Body Repair Manual
DEFENDE
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04
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Body Repair Manual
NEW RANGE ROVER
This manual covers vehicles from
introduction 1995
01 INTRODUCTION
04 GENERAL SPECIFICATION DATA
60 FRONT SUSPENSION
75 SUPPLEMENTARY RESTRAINT SYSTEM
76 CHASSIS AND BODY
77 PANEL REPAIRS
Published by Rover Technical Communication
P O Box 47, Cowley, OXFORD, OX45NL
ï›™ 1996 Rover Group Limited
Publication part no. LRL 0085ENG
INTRODUCTION
1
INFORMATION
INTRODUCTION
This Body Repair Manual is designed to provide the
experienced bodyshop technician with the information
required to carry out efficient and cost effective
repairs.
To assist in the use of this Manual, the section title is
given at the top and the relevant sub-section at the
bottom of each page.
The individual items comprising operations are to be
followed in the sequence in which they appear, see
BODY and SRS sections. Items numbers in the
illustration are referred to in the text. Adjustment and
repair operations include reference to Service Tool
numbers. Each adjustment or repair operation is given
its Service Repair Operation number.
The repair operations cover replacement of the
relevant welded panels and panel assemblies on the
vehicle, see PANEL REPAIRS. The sequence of
operations progresses from the front to the rear of the
vehicle. Each operation details any special points to
observe when replacing a welded panel, together with
cross-references to the relevant trim items to be
removed and replaced for access.
DIMENSIONS
The dimensions quoted are to design engineering
specification with service limits where applicable.
REFERENCES
References to the LH or RH side given in this Manual
are made when viewing the vehicle from the rear.
With the engine and gearbox assembly removed, the
water pump end of the engine is referred to as the
front.
WARNINGS, CAUTIONS and NOTES have the
following meanings:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of injury.
CAUTION: Calls attention to procedures
which must be followed to avoid damage
to components.
NOTE: Gives helpful information.
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that Land Rover parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement parts
and accessories: Safety features embodied in the
vehicle may be impaired if other than Land Rover
parts are fitted. In certain territories, legislation
prohibits the fitting of parts not to the vehicle
manufacturer’s specification. Torque spanner values
given in the Workshop Manual must be strictly
adhered to. Locking devices, where specified, must be
fitted. If the efficiency of a locking device is impaired
during removal it must be replaced with a new one.
Certain fasteners must not be re-used. These
fasteners are specified in the Workshop Manual.
Owners purchasing accessories while travelling
abroad should ensure that the accessory and its fitted
location on the car conform to legal requirements.
The terms of the vehicle Warranty may be invalidated
by the fitting of other than Land Rover recommended
parts.
All Land Rover recommended parts have the full
backing of the vehicle Warranty.
Land Rover dealers are obliged to supply only Land
Rover recommended parts.
01
INTRODUCTION NEW RANGE ROVER
2
INFORMATION
SPECIFICATION
Land Rover are constantly seeking to improve the
specification, design and production of their vehicles
and alterations take place accordingly. While every
effort has been made to ensure the accuracy of this
Manual, it should not be regarded as an infallible
guide to current specifications of any particular
vehicle.
This Manual does not constitute an offer for sale of
any particular vehicle. Land Rover dealers are not
agents of Land Rover and have no authority to bind
the manufacturer by any expressed or implied
undertaking or representation.
INTRODUCTION
1
BODY DIMENSIONS
ALIGNMENT JIG DIMENSIONS
1. 1190mm (46.8in.)
2. 1709mm (67.3in.)
3. 2527mm (99.6in.)
4. 4173mm (164.4in.)
5. 717mm (28.3in.)
6. 982.5mm (38.7in.)
7. 1328mm (52.3in.)
8. 1697mm (66.9in.)
9. 3159mm (124.5in.)
10. 1340mm (52.8in.)
11. 1302mm (51.3in.)
12. 665mm (26.2in.)
13. 1400mm (55.2in.)
14. 2364mm (93.1in.)
15. 1803mm (71.0in.)
A = No. 1 body mount RH and LH
B = Front spring seat RH and LH
C = No. 2 body mount RH and LH
D = Front crossmember piercing RH and LH
E = Front radius arm mounting bracket RH and LH
F = No. 3 body mount RH and LH
G = Rear composite link mounting bracket RH and
LH
H = No. 5 body mount RH and LH
All dimensions taken at centre line of set screw or set screw hole.
01
INTRODUCTION NEW RANGE ROVER
2
BODY DIMENSIONS
Straightening
Whenever possible, structural members should be
cold straightened under tension. Do not attempt to
straighten with a single pull, but rework the damaged
area using a series of pulls, releasing tension between
each stage and using the opportunity to check
alignment.
Body jig
Unless damage is limited to cosmetic panels, all repair
work to body members must be carried out on a body
jig, to ensure that impact damage has not spread into
more remote parts of the body structure. Mounting on
a jig will also ensure that the straightening and panel
replacement procedures do not cause further
distortion. If original dimensions cannot be
satisfactorily restored by these methods, damaged
structural members should be replaced. Damaged
areas should be cut away using a high speed saw,
NOT an oxy-acetylene torch.
As a rule, body dimensions are symmetrical about the
centre line. A good initial check for distortion is
therefore to measure diagonally and to investigate
apparent differences in dimensions.
Inspection
Every accident produces individual differences in
damage. Each repair is influenced by the extent of the
damage and by the facilities and equipment available
for its rectification.
Most accident damage can be visually inspected and
the approximate extent of the damage assessed.
Sometimes deformation will extend beyond the area
of direct damage, and the severity of this must be
accurately established so that steps may be taken to
restore critical body components to their original
dimensions.
An initial check of critical dimensions can be carried
out by means of drop checks or (preferably) trammels.
Gauges are available which will check accurately for
body twist. Where repairs necessitate renewal of a
critical body component it is recommended that a
body jig is used.
GENERAL SPECIFICATION DATA
1
INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN)
An adhesive label containing the Vehicle Identification
Number and the recommended maximum vehicle
weights is located on the left hand side of the bonnet
locking platform.
The number is also stamped on the right side of the
chassis forward of the spring mounting turret.
Key to Vehicle Identification Number Plate
A. VIN (17 digits)
B. Maximum permitted laden weight for vehicle
C. Maximum vehicle and trailer weight
D. Maximum road weight-front axle
E. Maximum road weight-rear axle
In addition the VIN is stamped on a plate which is
visible through the left side of the windscreen.
Federal (USA) vehicle identification number
An adhesive label containing the Vehicle Identification
Number, date of manufacture and gross axle weight
ratings is fixed to the lock face of the front left hand
door. The information includes wheel and tyre sizes
and tyre pressures at gross axle weight ratings.
04
GENERAL SPECIFICATION DATA NEW RANGE ROVER
2
INFORMATION
LOCATION OF IDENTIFICATION NUMBERS
Engine serial number - V8 engine
Stamped on a cast pad on the cylinder block, between
numbers 3 and 5 cylinders.
NOTE: The engine compression ratio is
stamped above the serial number.
Engine serial number - BMW Diesel engine
Stamped on the LH side of the cylinder block above
the sump.
Main gearbox R380 - 5 speed
Stamped on a cast pad on the bottom right hand side
of the gearbox.
Automatic gearbox ZF4HP22
Stamped on a plate riveted to the bottom left hand
side of the gearbox casing.
GENERAL SPECIFICATION DATA
3
INFORMATION
Transfer gearbox-Borg Warner
Stamped on a plate attached to the gearbox casing,
between filler/level and drain plug.
Front and rear axle
Stamped on the left hand axle tubes.
Vehicle identification number (VIN)
Made up of 17 digits, these numbers are used to
identify manufacturer, model range, specification,
body type, engine, transmission/steering, model year,
plant and build sequence number and serve to identify
the vehicle.
This example shows the sequence:
European code
SALLPAMJ7MA
S Europe
AL UK
LP Range Rover
A European Spec.
M 4 Door Station Wagon
J 4.6 Litre Fuel Injection
7 Manual right steering
M 1995 Model Year
A Solihull
Federal (USA) code
SALPV1242SA
S Europe
AL UK
P Range Rover
V North America Spec.
1 4 Door Station Wagon
2 4.0 Litre fuel injection
4 Automatic, Left Hand Steering
2 Check Digit
S 1995 Model Year
A Solihull
04
GENERAL SPECIFICATION DATA NEW RANGE ROVER
4
INFORMATION
SAFETY INSTRUCTIONS
Jacking
The recommended jacking points are given in
LIFTING AND TOWING.Always ensure that any lifting
apparatus has adequate load and safety capacity for
the weight to be lifted. Ensure the vehicle is standing
on level ground prior to lifting or jacking. Apply the
handbrake and chock the wheels.
Never rely on a jack as the sole means of support
when working beneath the vehicle. Use additional
safety supports beneath the vehicle.
Do not leave tools, lifting equipment, spilt oil, etc.
around or on the work bench area.
Precautions against damage
Always fit wing and seat covers before commencing
work. Avoid spilling brake fluid or battery acid on
paintwork. Wash off with water immediately if this
occurs.
Disconnect the battery earth lead before starting work.
See ELECTRICAL PRECAUTIONS.
Always use the recommended service tool or a
satisfactory equivalent where specified.
Protect exposed bearing and sealing surfaces and
screw threads from damage.
Brake Hydraulics
WARNING: It is imperative that the correct
brake fittings are used and that threads of
components are compatible.
Always use two spanners when slackening or
tightening brake pipe or hose connections. Ensure
that hoses run in a natural curve and are not kinked or
twisted. Fit brake pipes securely in their retaining clips
and ensure that the pipe run cannot contact a
potential chafing point.
Containers used for hydraulic fluid must be kept
absolutely clean. Do not store hydraulic fluid in an
unsealed container; it will absorb water and in this
condition will be dangerous to use. Do not allow
hydraulic fluid to be contaminated with mineral oil, or
use a container which has previously contained
mineral oil. Do not re-use fluid from the system.
Always use clean brake fluid or a recommended
alternative to clean hydraulic components. Fit a
blanking cap to an hydraulic union and a plug to its
socket after removal to prevent the ingress of dirt.
Absolute cleanliness must be observed with hydraulic
components.
Engine coolant caps and plugs
Extreme care is necessary when removing engine
coolant caps and plugs when the engine is hot and
especially if it is overheated. To avoid the possibility of
scalding allow the engine to cool before attempting
coolant cap or plug removal.
Cleaning components
Always use the recommended cleaning agent or
equivalent.
Do not use degreasing equipment for components
containing items which could be damaged by the use
of its process. Whenever possible clean components
and the area surounding them before removal. Always
observe scrupulous cleanliness when cleaning
dismantled components.
GENERAL SPECIFICATION DATA
5
INFORMATION
FUEL HANDLING PRECAUTIONS
The following information provides basic precautions
which must be observed if fuel is to be handled safely.
It also outlines the other areas of risk which must not
be ignored.
This information is issued for basic guidance only, and
in any case of doubt, appropriate enquiries should be
made of your local Fire Officer or Fire Department.
Fuel vapor is highly flammable and in confined spaces
is also very explosive and toxic.
When fuel evaporates it produces 150 times its own
volume in vapor, which when diluted with air becomes
a readily ignitable mixture. The vapor is heavier than
air and will always fall to the lowest level. It can readily
be distributed throughout a workshop by air current,
consequently, even a small spillage of fuel is very
dangerous.
Always have a fire extinguisher containing FOAM CO
2
GAS, or POWDER close at hand when handling fuel,
or when dismantling fuel systems and in areas where
fuel containers are stored.
WARNING: lt is imperative that the battery
is not disconnected during fuel system
repairs as arcing at the battery terminal
could ignite fuel vapour in the atmosphere.
Always disconnect the vehicle battery BEFORE
carrying out work on the fuel system.
Whenever fuel is being handled, transferred or
stored, or when fuel systems are being dismantled
all forms of ignition must be extinguished or
removed, any leadlamps used must be flame proof
and kept clear of spillage.
No one should be permitted to repair components
associated with fuel without first having had fuel
system training.
Hot fuel handling precautions
WARNING: Before commencing any
operation requiring fuel to be drained from
the fuel tank, the following procedure must
be adhered to:
1. Allow sufficient time for the fuel to cool, thus
avoiding contact with hot fuels.
2. Vent the system by removing the fuel filler cap in
a well ventilated area. Refit the filler cap until the
commencement of fuel drainage.
Fuel transfer
WARNING: Fuel must not be extracted or
drained from any vehicle while it is
standing over a pit.
The transfer of fuel from the vehicle fuel tank must be
carried out in a well ventilated area. An approved
transfer tank must be used according to the transfer
tank manufacturer’s instructions and local regulations,
including attention to grounding of tanks.
Fuel tank removal
A FUEL VAPOUR warning label must be attached to
the fuel tank upon removal from the vehicle.
Fuel tank repair
Under no circumstances should a repair to any tank
be attempted.
04
GENERAL SPECIFICATION DATA NEW RANGE ROVER
6
INFORMATION
ELECTRICAL PRECAUTIONS
General
The following guidelines are intended to ensure the
safety of the operator whilst preventing damage to the
electrical and electronic components fitted to the
vehicle. Where necessary specific precautions are
detailed in the relevant sections of this Manual which
should be referred to prior to commencing repair
operations.
Equipment - Prior to commencing any test procedure
on the vehicle ensure that the relevant test equipment
is working correctly and any harness or connectors
are in good condition. This particularly applies to
mains lead and plugs.
WARNING: Before commencing work on
an ignition system all high tension
terminals, adaptors and diagnostic
equipment for testing should be inspected to
ensure that they are adequately insulated and
shielded to prevent accidental personal contacts
and minimise the risk of shock. Wearers of
surgically implanted pacemaker devices should
not be in close proximity to ignition circuits or
diagnostic equipment.
Polarity - Never reverse connect the vehicle battery
and always observe the correct polarity when
connecting test equipment.
High Voltage Circuits - Whenever disconnecting live ht
circuits always use insulated pliers and never allow
the open end of the ht lead to come into contact with
other components, particularly ECU’s. Exercise
caution when measuring the voltage on the coil
terminals while the engine is running, as high voltage
spikes can occur on these terminals.
Connectors and Harness - The engine compartment
of a vehicle is a particularly hostile environment for
electrical components and connectors. Always ensure
these items are dry and oil free before disconnecting
and connecting test equipment. Never force
connectors apart either by using tools or by pulling on
the wiring harness. Always ensure locking tabs are
disengaged before removal and not orientation to
enable correct reconnection. Ensure that any
protective covers and substances are replaced if
disturbed.
Having confirmed a component to be faulty, switch off
the ignition and disconnect the battery. Remove the
component and support the disconnected harness.
When replacing the component keep oily hands away
from electrical connection areas and push connectors
home until any locking tabs fully engage.
Battery disconnecting
Before disconnecting the battery, switch off all
electrical equipment. If the radio is to be serviced,
ensure the security code has been deactivated.
CAUTION: To prevent damage to electrical
components ALWAYS disconnect the
battery when working on the vehicle
electrical system. The earth lead must be
disconnected first and reconnected last. Always
ensure that battery leads are routed correctly and
are not close to any potential chafing points.
Battery charging
Recharge the battery out of the vehicle and keep the
top well ventilated. While being charged or
discharged, and for approximately fifteen minutes
aferwards, batteries emit hydrogen gas. This gas is
inflammable.
Always ensure any battery charging is well ventilated
and that every precaution is taken to avoid naked
flames and sparks.
GENERAL SPECIFICATION DATA
7
INFORMATION
Jump starting
WARNING: Hydrogen and oxygen gases
are produced during normal battery
operation. This gas mixture can explode if
flames, sparks or lighted tobacco are brought
near battery. When charging or using a battery in
an enclosed space, always provide ventilation and
shield your eyes.
Keep out of reach of children. Batteries contain
sulphuric acid. Avoid contact with skin, eyes, or
clothing. Also, shield eyes when working near
battery to protect against possible splashing of
acid solution. In case of acid contact with skin,
eyes, or clothing, flush immediately with water for
a minimum of fifteen minutes. If acid is swallowed,
drink large quantities of milk or water, followed by
milk of magnesia, a beaten egg, or vegetable oil.
SEEK MEDICAL AID IMMEDIATELY.
To Jump Start - Negative Ground Battery
WARNING: To avoid any possibility of
injury use particular care when connecting
a booster battery to a discharged battery.
1. Position vehicles so that jump leads will reach,
ensuring that vehicles DO NOT TOUCH,
alternatively a fully charged slave battery may be
positioned on floor adjacent to vehicle.
2. Ensuring that ignition and all electrical
accessories are switched off, that parking brake
is applied and neutral is selected on a manual
gearbox, with an automatic gearbox select
neutral (N) or park (P) and then connect the
jump leads as follows;
A. Connect one end of first jumper cable to positive
(+) terminal of booster battery.
B. Connect other end of first jumper cable to
positive (+) terminal of discharged battery.
C. Connect one end of second jumper cable to
negative terminal of booster battery.
D. Connect other end of second jumper cable to a
good earth point on the engine, NOT TO
NEGATIVE TERMINAL OF DISCHARGED
BATTERY. Keep jumper lead away from moving
parts, pulleys, drive belts and fan blade
assembly.
WARNING: Making final cable connection
could cause an electrical arc which if
made near battery could cause an
explosion.
04
GENERAL SPECIFICATION DATA NEW RANGE ROVER
8
INFORMATION
3. If booster battery is installed in another vehicle,
start engine and allow to idle.
4. Start engine of vehicle with discharged battery,
following starting procedure in Owners’ Manual.
CAUTION: If vehicle fails to start within a
maximum time of 12 seconds, switch
ignition off and investigate cause. Failing
to follow this instruction could result in
irrepairable damage to catalysts.
5. Remove negative (-) jumper cable from the
engine and then terminal of booster battery.
6. Remove positive (+) jumper cable from positive
terminals of booster battery and discharged
battery.
Disciplines
Switch off ignition prior to making any connection or
disconnection in the system as electrical surge
caused by disconnecting ’live’ connections can
damage electrical components.
Ensure hands and work surfaces are clean and free of
grease, swarf, etc. as grease collects dirt which can
cause tracking or high-resistance contacts.
When handling printed circuit boards, treat them as
you would a disc - hold by the edges only; note that
some electronic components are susceptible to body
static.
Connectors should never be subjected to forced
removal or refit, especially inter-board connectors, as
damaged contacts will cause short circuit and
open-circuit conditions.
Prior to commencing test, and periodically during test,
touch a good earth (i.e. cigar lighter socket) to
discharge body static as some electronic components
are vulnerable to static electricity.
Grease for electrical connectors
All underbonnet and underbonnet connectors are
protected against corrosion by the application of a
special grease on production. Should connectors be
disturbed in service, repaired or replaced, a grease of
this type (available in 150gm tubes under Part No.
BAU 5811) should again be applied.
NOTE: The use of other greases must be
avoided as they can migrate into relays,
switches etc., contaminating the contacts
and leading to intermittent operation or failure.
GENERAL SPECIFICATION DATA
9
INFORMATION
BODY REPAIRS
Body shells are of welded construction and bolted to
the chassis frame. Front and rear sections of the shell
are designed as ’energy absorbing’ zones. This
means they are designed to deform progressively
when subjected to impact in order to minimise the
likelihood of injury to vehicle occupants.
It is essential that design dimensions and strength are
restored in accident rectification. It is important that
neither structural weakness nor excessive local
stiffness are introduced into the vehicle during body or
chassis repair.
Repairs usually involve a combination of operations
ranging from straightening procedures to renewal of
either individual panels or panel assemblies. The
repairer will determine the repair method and this
decision will take into account a balance of economics
between labour and material costs and the availability
of repair facilities in both equipment and skills. It may
also involve considerations of vehicles down-time,
replacement vehicle availability and repair turn-around
time.
It is expected that a repairer will select the best and
most economic repair method possible, making use of
the facilities available. The instructions given are
intended to assist a skilled body repairer by expanding
approved procedures for panel replacement with the
objective of restoring the vehicle to a safe running
condition and effecting a repair which is visually
acceptable and which, even to the experienced eye,
does not advertise the fact that it has been damaged.
This does not necessarily mean that the repaired
vehicle will be identical in all respects with original
factory build. Repair facilities cannot always duplicate
methods of construction used during production.
Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and suspension
geometry checked after completion and if necessary a
road test of the vehicle is carried out, particularly
where safety related items are concerned.
Where major units have been disconnected or
removed, it is necessary to ensure that fluid levels are
checked and topped up when necessary. It is also
necessary to ensure that the repaired vehicle is in a
roadworthy condition in respect of tyre pressures,
lights, washer fluid etc.
Body repairs often involve the removal of mechanical
and electrical units as well as associated wiring. See
BODY and SRS sections.
04
GENERAL SPECIFICATION DATA NEW RANGE ROVER
10
INFORMATION
Taking into consideration the differences in body
styles, steering and suspension systems as well as
engine and suspension layouts, the location of the
following components as applicable to a particular
vehicle is critical:
• Front suspension upper damper
mountings.
• Front suspension or sub frame mountings.
• Engine mounting on RH and LH chassis
longitudinals.
• Rear suspension upper damper mountings.
• Rear suspension mountings or lower
pivots.
• Steering rack mountings.
Additional points which can be used to check
alignment and assembly are:
• Inner holes in crossmember - side - main
floor.
• Holes in front longitudinals.
• Holes in extension - side member - front.
• Holes in rear longitudinals.
• Holes in rear lower panels or extension
rear floor.
• Fuel tank mountings.
Apertures for windscreen, backlight, bonnet and doors
can best be checked by offering up an undamaged
component as a gauge.
GENERAL SPECIFICATION DATA
11
INFORMATION
JACKING
The following instructions must be carried out before
raising the vehicle off the ground.
1. Use a solid level ground surface.
2. Apply parking brake.
3. Select ’P’ or 1st gear in main gearbox.
4. Select Low range in transfer gearbox.
CAUTION: To avoid damage occurring to
the under body components of the vehicle
the following jacking procedures must be
adhered to.
DO NOT POSITION JACKS OR AXLE STANDS
UNDER THE FOLLOWING COMPONENTS.
Body structure Air suspension pipes
Bumpers Fuel lines
Brake lines Front radius arms
Panhard rod Steering linkage
Rear Trailing links Fuel tank
Engine sump Gearbox bell housing
CAUTION: If supporting vehicle by the
front crossmember, the safety stands
must be postioned carefully to avoid
damage to air suspension pipes.
Vehicle jack
The jack provided with the vehicle is only intended to
be used in an emergency, for changing a tyre. Do
NOT use the jack for any other purpose. Refer to
Owner’s Manual for vehicle jack location points and
procedure. Never work under a vehicle supported by
the vehicle jack.
Hydraulic jack
A hydraulic jack with a minimum 1500 kg, 3,300 lbs
load capacity must be used.
CAUTION: Do not commence work on the
underside of the vehicle until suitable axle
stands have been positioned under the
axle.
Raise the front of the vehicle
1. Position cup of hydraulic arm under differential
casing.
NOTE: The differential casing is not
central to the axle. Care should be taken
when raising the front road wheels off the
ground as the rear axle has less sway stiffness.
04
GENERAL SPECIFICATION DATA NEW RANGE ROVER
12
INFORMATION
2. Raise front road wheels to enable an axle stand
to be installed under left hand axle tube.
3. Position an axle stand under right hand axle
tube, carefully lower jack until axle sits securely
on both axle stands, remove trolley jack.
4. Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5. Reverse procedure when removing vehicle from
stands.
Raise rear of vehicle
1. Position cup of hydraulic arm under differential
casing.
2. Raise vehicle to enable axle stands to be
installed under left and right hand axle tubes.
3. Lower jack until axle sits securely on axle
stands, remove trolley jack.
4. Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5. Reverse procedure when removing vehicle from
stands.
GENERAL SPECIFICATION DATA
13
INFORMATION
HYDRAULIC VEHICLE RAMP (FOUR POST)
Use only a ’drive on’ type ramp which supports vehicle
by its own road wheels. If a ’wheel-free’ condition is
required, use a ’drive on’ ramp incorporating a
’wheel-free’ system that supports under axle casings.
Alternatively, place vehicle on a firm, flat floor and
support on axle stands.
TWO POST VEHICLE RAMPS
The manufacturer of RANGE ROVER VEHICLES
DOES NOT recommend using ’Two Post’ ramps
that employ four adjustable support arms. These
are NOT considered safe for Range Rover
vehicles.
If vehicle is installed on a Two Post ramp
responsibility for safety of vehicle and personnel
performing service operations is in the hands of
the Service Provider.
DYNAMOMETER TESTING - VEHICLES WITH
ANTI-LOCK BRAKES (ABS)
WARNING: Do not attempt to test ABS
function on a dynamometer
Four wheel dynamometers
NOTE: Before testing a vehicle on a four
wheel dynamometer disconnect the valve
relay.
See Electrical Trouble Shooting
Manual.
The ABS function will not work, the ABS warning
light will illuminate. Normal braking will be
available.
Provided that front and rear rollers are rotating at
identical speeds and that normal workshop safety
standards are applied, there is no speed restriction
during testing except any that may apply to the tyres.
Two wheel dynamometers
IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.
NOTE: ABS will not function on a two
wheel dynamometer. The ABS light will
illuminate during testing. Normal braking
will be available.
If brake testing on a single rig is necessary it must be
carried out with propeller shaft to the rear axle
removed, AND neutral selected in BOTH main and
transfer boxes.
If checking engine performance, the transfer box must
be in high range and drive shaft to stationary axle
removed.
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GENERAL SPECIFICATION DATA NEW RANGE ROVER
14
INFORMATION
EMERGENCY TOWING
CAUTION: The New Range Rover has
permanent four-wheel drive. The following
instructions must be adhered to when
towing:-
Towing the vehicle on four wheels
If it is necessary to recover the vehicle by towing on
all four wheels, ’Transfer neutral’ MUST be selected.
1. With the starter key removed, insert a fuse of 5
amps or more in fuse position ’11’ in the RH seat
fuse box.
2. Turn the starter switch to position ’2’; the transfer
box will now automatically select neutral.
3. Wait until the message centre displays
’TRANSFER NEUTRAL’ and then turn the
starter switch off, position ’0’.
4. Turn the starter switch to position ’1’ to unlock
the steering and leave in this position while the
vehicle is being towed.
5. Secure tow rope to the front towing eye.
6. Release the parking brake.
CAUTION: The brake servo and power
assisted steering system will not be
functional without the engine running.
Heavier pedal pressure will be required to apply
the brakes, the steering system will require
greater effort to turn the front wheels.
The vehicle tow connection should be used only
in normal road conditions.
CAUTION: DO NOT remove the starter key
or turn the switch to position ’0’ when the
vehicle is in motion.
7. To reactivate the transfer box after towing, turn
the starter switch off to position ’0’ and remove
the fuse from position ’11’. On automatic
vehicles the transfer box will automatically
engage the Low or High gear range.
8. On manual vehicles, first press the range
change switch. The transfer box will then engage
the Low or High gear range.
Suspended tow by breakdown vehicle
CAUTION: To prevent vehicle damage,
front or rear propeller shaft MUST be
removed, dependant upon which axle is
being trailed.
9. To facilitate reassembly, first mark the propeller
shaft drive flanges at transfer box and axle.
10. Remove propeller shaft fixings and lift shaft from
vehicle.
11. If the front axle is to be trailed turn ignition key to
position ’1’ to release the steering lock.
CAUTION: If the rear axle is to be raised,
the steering wheel and/or linkage MUST be
secured in a straight ahead position. DO
NOT use the steering lock for this purpose.
GENERAL SPECIFICATION DATA
15
INFORMATION
TRANSPORTING THE VEHICLE BY TRAILER
If the vehicle should require transporting on a trailer or
the back of a lorry, the air suspension must be set to
’ACCESS’ before being lashed.
See FRONT
SUSPENSION, Description and operation.
Lashing eyes are provided on the front and rear
chassis cross members to facilitate the securing of the
vehicle, as shown.
CAUTION: DO NOT secure lashing hooks
or trailer fixings to any other part of the
vehicle.
CAUTION: If the air suspension cannot be
set to the ’ACCESS’ position, then the
vehicle must be lashed by its wheels and
not the lashing eyes.
Install vehicle on the trailer and apply park brake.
Select neutral in main gearbox; this will prevent
damage to the parking pawl of the automatic gearbox.
04
GENERAL SPECIFICATION DATA NEW RANGE ROVER
16
INFORMATION
VEHICLE DIMENSIONS
mm inches
Overall length 4713................................................................... 185.6
with Europe/UK towbar 4804........................................... 189.1
Overall width 1889.................................................................... 74.4
Overall height at standard profile 1817.5..................................... 71.6
Wheelbase 2745....................................................................... 108.1
Track:
Front 1540........................................................................ 60.6
Rear 1530........................................................................ 60.2
Turning circle between kerbs 1189 mm (39 ft)...........................................
STEERING
Power steering box
Make/type ZF type 8055, recirculating ball steering gear........................................................................
Steering wheel turns, lock-to-lock 3.2....................................
Steering pump
Make/type:
V8 engine ZF type 7691, vane type................................................................
Diesel engine ZF type7681, vane type..........................................................
Steering geometry
Steering wheel diameter 406.4mm (16 in.)..................................................
Toe-out measurement 0.6 to 1.80mm (0.02 - 0.07 in.)......................................................
Toe-out included angle 0˚ 5’ to 0˚ 15’.....................................................
Camber angle 0Ëš.................................................................. NOTE:
Castor angle 4Ëš..................................................................... Check at
Swivel pin inclination static 8Ëš............................................... kerbweight
GENERAL SPECIFICATION DATA
17
INFORMATION
VEHICLE WEIGHTS AND PAYLOAD
When loading a vehicle to its maximum (Gross Vehicle Weight), consideration must be taken of the vehicle kerb
weight and the distribution of the payload to ensure that axle loadings do not exceed the permitted maximum
values. It is the customer’s responsibility to limit the vehicle’s payload in an appropriate manner such that neither
maximum axle loads nor Gross Vehicle Weight are exceeded.
GROSS VEHICLE WEIGHT
Petrol Models Diesel Models
Front Axle 1320 kg (2910 lb).............................. 1320 kg (2910 lb).............
Rear Axle 1840 kg (4056 lb).............................. 1840 kg (4056 lb).............
Total 2780 kg (6129 lb)...................................... 2780 kg (6129 lb).............
Maximum Payload 603 kg (1329 lb)................. 596 kg (1314 lb)...............
EEC KERB WEIGHT AND DISTRIBUTION
4.0 Litre Manual 4.0 Litre Automatic 4.6 Litre Automatic
EEC Kerb Weight 2090 kg (4607 lb).................. 2100 kg (4629 lb)............. 2220 kg (4894 lb).............
Front Axle 1095 kg (2414 lb).............................. 1100 kg (2425 lb)............. 1165 kg (2568 lb).............
Rear Axle 995 kg (2193 lb).............................. 1000 kg (2204 lb)............... 1055 kg (2325 lb).............
2.5 Diesel Manual 2.5 Diesel Automatic
EEC Kerb Weight 2115 kg (4662 lb).................. 2130 kg (4695 lb).............
Front Axle 1110 kg (2447 lb).............................. 1120 kg (2469 lb).............
Rear Axle 1005 kg (2215 lb).............................. 1010 kg (2226 lb).............
NOTE: EEC KERB WEIGHT is the minimum vehicle specification plus full fuel tank and 75 kg
(165lb) driver.
NOTE: GROSS VEHICLE WEIGHT is the maximum all-up weight of the vehicle including driver,
passengers, and equipment. This figure is liable to vary according to legal requirements in certain
countries.
NOTE: MAXIMUM ROOF RACK LOAD (including weight of rack) 75 kg (165 lb) must be included in
total vehicle weight.
GENERAL SPECIFICATION DATA
1
BODY DIMENSIONS
ALIGNMENT JIG DIMENSIONS
1. 1190mm (46.8in.)
2. 1709mm (67.3in.)
3. 2527mm (99.6in.)
4. 4173mm (164.4in.)
5. 717mm (28.3in.)
6. 982.5mm (38.7in.)
7. 1328mm (52.3in.)
8. 1697mm (66.9in.)
9. 3159mm (124.5in.)
10. 1340mm (52.8in.)
11. 1302mm (51.3in.)
12. 665mm (26.2in.)
13. 1400mm (55.2in.)
14. 2364mm (93.1in.)
15. 1803mm (71.0in.)
A = No. 1 body mount RH and LH
B = Front spring seat RH and LH
C = No. 2 body mount RH and LH
D = Front crossmember piercing RH and LH
E = Front radius arm mounting bracket RH and LH
F = No. 3 body mount RH and LH
G = Rear composite link mounting bracket RH and
LH
H = No. 5 body mount RH and LH
All dimensions taken at centre line of set screw or set screw hole.
04
GENERAL SPECIFICATION DATA NEW RANGE ROVER
2
BODY DIMENSIONS
Straightening
Whenever possible, structural members should be
cold straightened under tension. Do not attempt to
straighten with a single pull, but rework the damaged
area using a series of pulls, releasing tension between
each stage and using the opportunity to check
alignment.
Body jig
Unless damage is limited to cosmetic panels, all repair
work to body members must be carried out on a body
jig, to ensure that impact damage has not spread into
more remote parts of the body structure. Mounting on
a jig will also ensure that the straightening and panel
replacement procedures do not cause further
distortion. If original dimensions cannot be
satisfactorily restored by these methods, damaged
structural members should be replaced. Damaged
areas should be cut away using a high speed saw,
NOT an oxy-acetylene torch.
As a rule, body dimensions are symmetrical about the
centre line. A good initial check for distortion is
therefore to measure diagonally and to investigate
apparent differences in dimensions.
Inspection
Every accident produces individual differences in
damage. Each repair is influenced by the extent of the
damage and by the facilities and equipment available
for its rectification.
Most accident damage can be visually inspected and
the approximate extent of the damage assessed.
Sometimes deformation will extend beyond the area
of direct damage, and the severity of this must be
accurately established so that steps may be taken to
restore critical body components to their original
dimensions.
An initial check of critical dimensions can be carried
out by means of drop checks or (preferably) trammels.
Gauges are available which will check accurately for
body twist. Where repairs necessitate renewal of a
critical body component it is recommended that a
body jig is used.
GENERAL SPECIFICATION DATA
1
COMPONENT LOCATION
ELECTRONIC CONTROL UNITS
1. Engine control module (ECM) (at RH of engine
bay)
2. ABS ECU (behind access plate at LH of
dashboard)
3. Cruise control ECU (behind fascia closing panel)
4. Diagnostic control unit (on centre tunnel)
5. Electronic suspension ECU (beneath LH front
seat)
6. Body electrical control module (BeCM) (beneath
RH front seat)
The electronic control units fitted to Land Rover
vehicles make it advisable to follow suitable
precautions prior to carrying out welding repair
operations. Harsh conditions of heat and vibration
may be generated during these operations which
could cause damage to the units. See ELECTRICAL
PRECAUTIONS section.
In particular, it is essential to follow the appropriate
precautions when disconnecting or removing the SRS
diagnostic unit. See SUPPLEMENTARY RESTRAINT
SYSTEM, Precautions section.
GENERAL SPECIFICATION DATA
1
SEALING AND CORROSION PROTECTION
APPROVED MATERIALS
MATERIAL MANUFACTURER
3M:
Bodygard (08158, 08159)
Weld Thru’ Sealer (08625)
Drip-Chek Clear (08401)
Drip-Chek Heavy (08531)
Flexseal Polyurethane Seam Sealer (08684, 08689, 08694)
Polyurethane Sealer (sachet) (08703, 08783, 08788)
Super Seam Sealer (08537)
Sprayable Sealer (08800, 08823)
Bolted Panel Sealer (08572)
Body Caulking (08568)
Windscreen Sealer (08509)
Gurit-Essex:
Betafill Clinch and Brushable Sealer (Black) (10215)
Betafill Clinch and Brushable Sealer (Grey) (10211)
Betafill Clinch and Brushable Sealer (White) (10220)
Clinch Joint and Underbody Coating (Grey) (10101)
Clinch Joint and Underbody Coating (Beige) (10707)
SEALERS Kent Industries:
Leak-Chek Clear Putty (10075)
PPG:
Polyurethane Seam Sealer (6500)
Polyurethane Seam Sealer (92)
Terostat Preformed Strip (V11)
Terolan Light Seam Sealer
Teroson:
Terolan Special Brushable Seam Sealer
Terostat 1K PU Seam Sealer (SE20)
Terostat Sprayable Seam Sealer (9320)
Unipart:
Promatch Sealing Compound (UBS605, UBS606, UBS607)
Promatch Bolted Panel Sealer (UBS111)
Wurth:
Sealing Compound (890100, 890101, 890102, 890103, 890104,
890105, 890106)
Astrolan Engine Bay Wax & Cosmetic Wax (DA3241/DA3243)
Weld Thru’ Coating (05913)
04
GENERAL SPECIFICATION DATA NEW RANGE ROVER
2
SEALING AND CORROSION PROTECTION
Approved materials (continued)
MATERIAL MANUFACTURER
3M:
Automotive Structural Adhesive (08120)
Aerosol Auto Adhesive (Trim) (08080)
ADHESIVES Spray 80 Adhesive (08090)
Ciba-Geigy:
Structural Two-Part Epoxy (XB5106/XB5107)
3M:
Spray Schutz (08877)
Body Schutz (08861)
Stone Chip Coating (Textured) (08868, 08878, 08879)
Stone Chip Coating (Smooth) (08158, 08160, 08886)
Croda:
Crodapol Brushable Underbody Sealer (PV75)
UNDERBODY COATINGS Underbody Wax (PW61)
Dinol:
Tectacote Underbody Wax (205)
Teroson:
Terotex Underseal CP02 (9320)
Unipart:
Promatch Underbody Schutz (UBS410)
Promatch Underbody Wax (PW61)
3M:
Inner Cavity Wax (Transparent) (08909, 08919, 08929)
Inner Cavity Wax (Amber) (08901, 08911, 08921)
Dinol:
Engine Bay & Cosmetic Wax/Lacquer (PW197)
WAX COATINGS Cavity Wax (PW57)
Engine Bay Cosmetic Wax/Lacquer (4010)
Unipart:
Promatch Cavity Wax (UBS508)
GENERAL SPECIFICATION DATA
3
SEALING AND CORROSION PROTECTION
Approved materials (continued)
MATERIAL MANUFACTURER
3M:
Zinc Spray (09113)
WELD-THROUGH PRIMERS ICI:
Zinc Rich Primer (P-565 634)
3M:
Flexible Parts Repair Material (05900)
Cleaner and Wax Remover (1 litre) (08984)
Waterproof Cloth Tape (Y387/YS3998)
GENERAL MATERIALS Teroson:
Sprayable Aerosol, Water Shedder Repair
Unipart:
Waterproof Tape (GWS121)
Urethane Butyl Tape (BHM605)
04
GENERAL SPECIFICATION DATA NEW RANGE ROVER
4
SEALING AND CORROSION PROTECTION
MATERIALS APPLICATIONS
Joint Types:
1. Between bolted panels
2. Between bolted panel edges
3. Between spot welded panels
4. Between spot welded panel edges
5. Between bonded panels
6. Between bonded panel edges
7. Clinch joints (type a)
8. Clinch joints (type b)
9. Clinch joints (type c)
10. Gaps between panels (type a)
11. Gaps between panels (type b)
GENERAL SPECIFICATION DATA
5
SEALING AND CORROSION PROTECTION
Materials applications (continued)
MANUFACTURER MATERIAL/JOINT TYPE
ICI P565 634 Zinc rich primer. Between bolted and spot welded panels,
3M 09113 clinch joints (type a). Brush or spray application.
Teroson Terostat V11 Preformed strip. Between bolted panels. Hand application.
Kent Industries 10075
3M 08401
3M 08572
3M 08684
3M 08689
3M 08694
3M 08703 Seam sealer. Between bolted panel edges. Applicator gun/by hand.
3M 08783
3M 08788
PPG Polyurethane 6500
Teroson 92
Terolan Light
Terostat 1K PU
Terostat 9320
Unipart UBS 605/6/7
Wurth 890100/1/2/3/4/5/6
Ciba-Geigy XBS106/7 Structural adhesive. Between spot welded and bonded panels,
3M 08120 clinch joints (type a). Applicator gun, caulking gun.
3M 08625 Seam sealer. Between spot welded panels. Applicator gun.
Kent Industries 10075
3M 08401
3M 08684
PPG 6500
Teroson 92 Seam sealer light. Between spot welded panel edges.
Terolan Light Hand applicator gun.
Terostat 9320
Terostat 1K PU
Unipart UBS605/6/7
Wurth 890100/1/2/3/4/5/6
04
GENERAL SPECIFICATION DATA NEW RANGE ROVER
6
SEALING AND CORROSION PROTECTION
Materials applications (continued)
MANUFACTURER MATERIAL/JOINT TYPE
Ciba-Geigy XBS106/7 Structural adhesive. Between bonded panels. Caulking gun.
3M 08120
PPG 6500
Teroson 92
Terostat 9320 Semi-structural adhesive/anti-flutter material. Between
Unipart UBS605/6/7 bonded panels. Caulking gun.
Wurth 890100/1/2/3/4/5/6
Kent Industries 10075
3M 08401
3M 08694
PPG 6500 Seam sealer light. Between bonded panel edges.
Teroson 92 Hand applicator gun.
Teroson Light
Teroson 9320
Terostat 1K PU
Unipart UBS605/6/7
Wurth 890100/1/2/3/4/5/6
Gurit-Essex 10211
Gurit-Essex 10215
Gurit-Essex 10220
3M 08531 Seam sealer. Clinch joints (type b). Caulking gun.
3M 08537
3M 08703
3M 08783
3M 08788
GENERAL SPECIFICATION DATA
7
SEALING AND CORROSION PROTECTION
Materials applications (continued)
MANUFACTURER MATERIAL/JOINT TYPE
Kent Industries 10075
3M 08401 Seam sealer light. Clinch joints (type c). Caulking gun,
3M 08531 hand applicator gun.
Teroson Terolan Light
Kent Industries 10075
3M 08401
3M 08684
3M 08689
3M 08694 Seam sealer light. Gaps between panels (type a).
PPG 6500 Hand applicator gun.
Teroson 92
Terolan Light
Terostat 1K PU
Unipart UBS605/6/7
Wurth 890100/1/2/3/4/5/6
Kent Industries 10075
Kent Industries Putty
3M 08401
3M 08531
3M 08568
3M 08684
3M 08689 Seam sealer heavy. Gaps between panels (type b). Hand
3M 08694 applicator gun, applicator tube or caulking gun.
PPG 6500
Teroson 92
Terolan Light
Terostat 9320
Terostat 1K PU
Unipart UBS605/6/7
Wurth 890100/1/2/3/4/5/6
Gurit-Essex 10101
Gurit-Essex 10707
3M 08537
Gurit-Essex 10211
Gurit-Essex 10215 Brushable sealer. Overlap joints (e.g. floor pans).
Gurit-Essex 10220 Brush.
Teroson Brushable Sealer
Croda PW57
3M Cavity Waxes Cavity wax. Box members, sills. Injection equipment.
Unipart UBS508
04
GENERAL SPECIFICATION DATA NEW RANGE ROVER
8
SEALING AND CORROSION PROTECTION
Materials applications (continued)
MANUFACTURER MATERIAL/JOINT TYPE
Croda PV75
3M 08861
3M 08877 Underbody sealing coat. Underbody. Schutz gun, aerosol.
Teroson Terotex Underseal
Unipart UBS410
Croda PW61
Dinol 205 Underbody wax coat. Underbody. Spray gun or brush.
Unipart PW61
Astors 3241/3
Croda PW197 Engine bay cosmetic wax/lacquer. Spray gun or brush.
Dinol 4010
3M Stone Chip Anti-chip coating. Sill panels. Schutz gun.
Coatings
3M 05900 Plastic Two-pack material. Repair of plastic parts.
Parts Repair Material Spreader or palette knife.
3M 08509 Dry glazed windscreen sealer. Applicator gun.
Unipart BHM605 Urethane butyl sealer for direct glazing. Caulking gun.
3M YS3998
3M Y387 Waterproof tape for sealing apertures. Hand application.
Unipart GS121
Evode Evo-Stik
3M 08030
3M 08034 Trim fixing adhesive. Brush or aerosol.
3M 08080
3M 08090
3M 08984 Adhesive cleaner/wax remover. Hand application with cloth.
GENERAL SPECIFICATION DATA
9
SEALING AND CORROSION PROTECTION
APPLICATION EQUIPMENT
SATA Schutz Gun Model UBE
Specifications:
Air consumption 200 litres/min. (7cu/ft. min.) @ 45PSI...............................................................
Weight 660grams (23.3oz)..............................................................................
Manufactured and supplied by:
Sata Gmbh
Minden Industrial Ltd.
16 Greyfriars Road
Moreton Hall
Bury St. Edmunds
Suffolk IP32 7DX
Tel. (01284) 760791
The Sata Schutz Gun is approved for the re-treatment
of vehicle underbody areas with protective coatings as
supplied in 1-litre (1.76pt.), purpose-designed,
’one-way’ containers. The screw thread fitting (female
on the gun) will fit most Schutz-type packs.
Full operating details are supplied with the equipment.
NOTE: Always clean gun after use with the
appropriate solvent.
Sata HKD1 Wax Injection Equipment
The Sata HKD1 is approved by Rover for use in all
cavity wax re-treatment operations. The equipment
comprises a high quality forged gun with 1-litre
capacity pressure feed container, a flexible nylon
lance, 1100mm (43.3in.) straight steel lance and
hooked wand lance. A quick-change coupling is a
standard fitting to enable lances to be easily
interchanged. The lances each have their own spray
pattern characteristics to suit the type of box section
to be treated.
The Sata HKD1 is covered by a 12 month warranty.
All replacement parts and service are obtainable from
the suppliers.
04
GENERAL SPECIFICATION DATA NEW RANGE ROVER
10
SEALING AND CORROSION PROTECTION
Cooper Pegler Falcon Junior Pneumatic (Airless)
Manufacturer and supplier:
Cooper Pegler & Co. Ltd.
Burgess Hill
Sussex RH15 9LA
Tel. 04 446 42526
Intended primarily for applying transit wax, the Falcon
Junior pneumatic sprayer has a 5-litre (1 gal.)
container with integral hand pump. This high quality
unit provides a simple and effective means of wax
spraying without the need for compressed air or
additional services.
A selection of nozzles, lances and hoses together with
a trigger valve assembly incorporating a filter enable
the sprayer to be used in a variety of applications.
These include general maintenance, wax injection and
paint application. All parts are fully replaceable and
include a wide range of nozzle configurations.
The Falcon Junior is fitted with Viton seals and is
guaranteed for 12 months.
3M Application Equipment
Manufacturer:
3M UK PLC
Automotive Trades Group
3M House
PO Box 1
Market Place
Bracknell
Berks. RG12 1JU
Tel. (01344) 858611
All 3M equipment is available from local trade factors
or 3M refinishing factors.
3M Caulking Gun 08002
A lightweight, robust metal skeleton gun designed to
accommodate 325mm (12.8in.) cartridge for
dispensing sealants etc. This gun facilitates rapid
cartridge loading and features a quick-release lever
for accurate material ejection and cut-off control.
3M Pneumatic Cartridge Gun 08012
An air line fed gun for application of 3M cartridge
products. Excellent ease of application for a smooth
sealant bead, and incorporates a regulator valve for
additional control.
Other 3m applicator equipment available:
3M Pneumatic Applicator Guns
Air line fed gun for application of 3M sachet sealers
(Part No. 08006 for 200ml [6fl/oz.] and 310ml [9fl/oz.]
sachets, and Part No. 08007 for all size sachets
including 600ml [18fl/oz.]).
3M Applicator Gun 08190
For application of 3M Structural Adhesive 08120.
3M Inner Cavity Wax Applicator Gun
Features 750mm (29.6in.) flexible tube and using
1-litre (1.76pt.) canisters, this approved equipment is
available from all 3M refinishing factors.
Other 3m applicator equipment available:
Heavy Duty Manual Gun.
GENERAL SPECIFICATION DATA
11
SEALING AND CORROSION PROTECTION
MATERIALS GUIDE
3M Automotive Structural Adhesive 08120
a two-part epoxy structural adhesive, with ’automix’
twin-cartridge dispenser. For doorskin and for bonding
panel stiffeners. Supplied as twin pack for use in small
trigger gun (No. 08190).
3M Bolted Panel Sealer 08572
Preformed strip 20mm (0.8in.) wide x 2mm (0.08in.)
thick supplied in 4.6 metre (81.2in.) reels.
Permanently flexible with good adhesion, for sealing
wing to body joints and other bolted or riveted panels.
3M Body Caulking 08568
Thumb-applied sealing compound supplied in
60-packs of preformed strips 300mm (11.8in.) long x
6mm (0.24in.) wide. For sealing large openings and
fissures. Non-hardening, does not dry out or crack,
can be overpainted immediately.
3M Drip-Chek Sealer Heavy 08531
For use on vertical fissures and seams up to 3mm
(0.12in.) wide for a firm but flexible seal which will not
harden or shrink. Self-levelling, will not sag on vertical
surfaces. May be worked with a tool or smoothed with
a wet finger.
Supplied in 150ml (4.5fl/oz.) tubes.
3M Drip-Chek Sealer Clear 08401
An easily flowing sealer similar to Drip-Chek Heavy
but of clear consistency. Ideal for an almost invisible
spot weal over finished paintwork. Can be overpainted
or even mixed with paint colour to form a self-coloured
sealant.
Supplied in 150ml (4.5fl/oz.) tubes.
3M Super Seam Sealer 08537
A brushable sealer designed to simulate original
factory-applied sealer on all overlap joints such as
floor pans, wheel arches, boot and load space seams
and fuel filler cap surrounds. Resistant to oil, petrol
and water. Should be brushed on in ONE direction
only for best results.
WARNING: Must be stored under
conditions applicable to highly flammable
materials.
3M Flexseal 08684, 08689 AND 08694
A high solid, non-shrinking, polyurethane body sealer
for use in either a hand gun or pneumatic applicator
gun. Excellent adhesion and sealing properties.
Resistant to oil, petrol and water. Supplied in 310ml
(9fl/oz.) cartridges and in a choice of black, white or
grey.
3M Polyurethane Sachet Sealer 08703, 08783,
08788
Similar to Flexseal polyurethane but available in
collapsible foil sachets in 310ml (9fl/oz.) and 600ml
(18fl/oz.) sizes with a choice of three colours: black,
grey or white.
3M Windscreen Sealer 08509
Non-hardening sealant for dry-glazed,
weatherstrip-type windscreens. Applied with applicator
gun.
Supplied in 310ml (9fl/oz.) cartridges.
3M Spray Schutz 08877, Body Schutz 08861
Flexible, rubberised, fast-drying coating which dries to
a black textured finish.
Spray Schutz supplied in 600ml (18fl/oz.) aerosols.
Spray Schutz and Body Schutz also supplied in 1-litre
(1.76pt.) cartridges to fit Schutz Gun.
04
GENERAL SPECIFICATION DATA NEW RANGE ROVER
12
SEALING AND CORROSION PROTECTION
3M Flexible Parts Repair Material 05900
A fast-curing, two-part system for repairing minor
damage to plastic bumpers, spoilers, valances etc.
Dries in 30 mins.
Supplied as two-pack 320ml (10fl/oz.) kit.
3M Weld Thru’ SEALER 08625
For anti-corrosion protection between spot welded
panels. Brush application.
Supplied in 1-litre (1.76pt.) canisters.
3M Bodygard
Rubber-based, stone chip protective coating for
panels. Fast drying, low bake compatible and may be
overpainted. Varying textures obtainable depending
on type of finish required. Available in black (1-litre
[1.76pt.] pack 08858, aerosol 08158) or grey (1-litre
[1.76pt.] pack 08859, aerosol 08159).
3M Inner Cavity Wax
For protective coating on inner panels. Excellent
anti-corrosion properties. Available in transparent or
amber consistencies, and 1-litre (1.76pt.) canister or
500ml (0.88pt.) aerosol packs.
3M Zinc Spray 09113
Anti-corrosive coating for spot welding applications on
joints and seams. Supplied in 500ml (0.88pt.) aerosol
packs.
3M Waterproof Cloth Tape YS3998
Black waterproof tape for sealing door apertures and
body box section access holes. Long-lasting,
moisture-resistant adhesive will withstand immersion
in water.
Supplied in 50-metre (164.2ft.) rolls in a variety of
widths.
3M Adhesive Cleaner and Wax Remover 08984
For surface preparation before application of most
types of adhesive, coating and sealant, also for
removal of tar, silicone polish, wax, grease and oil.
Non-staining. May also be used for cleaning adhesive
remnants from sander disc backing pads.
Supplied in 1-litre (1.76pt.) canisters.
ELECTRONIC AIR SUSPENSION
1
DESCRIPTION AND OPERATION
ELECTRONIC AIR SUSPENSION - EAS
Description
The Range Rover concept of air supension is already
well established, the system fitted to the New Range
Rover is broadly similar. Progressive development
has resulted in added features to improve the control
and operation of the system.
Air springs provide a soft and comfortable feel to the
ride of the vehicle. The use of a microprocessor to
control the system exploits the advantages of air
suspension.
The system provides a near constant ride frequency
under all load conditions resulting in:
• Improved ride quality
• Consistency of ride quality
• Constant ride height
• Improved headlamp levelling
The system provides five ride height settings plus self
levelling. Each setting is automatically maintained at
the correct height by the system logic with the
minimum of driver involvement. Vehicle height is
sensed by four rotary potentiometer type height
sensors. Height information from each sensor signals
the electronic control unit (ECU) to adjust each air
spring by switching the solenoid valves to hold, add or
release air.
The five height settings are as follows:
Standard: Profile
Low profile: 25 mm (1 in.) below standard.
Access: 65 mm (2.6 in.) below standard. Crawl: It is
possible to drive at the access ride height at speeds
less than 32 km/h (20 mph), where headroom is
restricted.
High profile: 40 mm (1.6 in.) above standard.
Extended profile: 70 mm (2.75 in.) above standard.
This setting is not manually selectable.
Self levelling
On a coil sprung vehicle the effect of adding weight is
for the vehicle to lean either from front to back or side
to side unless the increased weight is evenly spread.
With air suspension, the system detects this body lean
and automatically compensates for it. The vehicle will
self level to the lowest corner height for 20 seconds
each time the driver exits vehicle and closes the
doors.
The system will check vehicle height every 6 hours
and make minor corrections, not exceeding 8 mm,
(0.31 in) as necessary.
When unloading through the tailgate the system will
self level to compensate for the decreased load after
door closure.
NOTE: If the vehicle is parked on uneven
ground or with a wheel or wheels on the
kerb, self levelling will lower the vehicle to
the lowest spring height.
CAUTION: The underside of the vehicle
must be kept clear of any obstacles while
the vehicle is parked, as self levelling may
result in a reduced trim height.
WARNING: Before commencing work
which requires access to the underside or
wheel arches of the vehicle, the
suspension must be allowed to relevel.
Relevelling is achieved by opening and closing of
any of the side doors, while all other doors and
tail gate remain closed, and the ignition off.
EAS must be set in ’high-lock’ using TestBook,
during any work which does not require chassis
to axle displacement. This will hold the
suspension in extended profile position, until
reset by TestBook.
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FRONT SUSPENSION NEW RANGE ROVER
2
DESCRIPTION AND OPERATION
LOCATION OF COMPONENTS
Key to location of components
1. Electrical control unit
2. Compressor
3. Air dryer
4. Valve block
5. Reservoir
6. Height sensors front
7. Height sensors rear
8. Front air spring
9. Rear air spring
10. Relays, fuses
11. Driver controls
ELECTRONIC AIR SUSPENSION
3
DESCRIPTION AND OPERATION
DESCRIPTION OF COMPONENTS
Electrical control unit - ECU
The ECU is located underneath the front left hand
seat. The ECU maintains the requested vehicle ride
height by adjusting the volume in each air spring. It is
connected to the cable assembly by a 35 way
connector. To ensure safe operation the ECU has
extensive on board diagnostic and safety features.
The ECU must be replaced in case of failure.
Air compressor
NOTE: The air compressor and valve block
are contained in the under bonnet unit
mounted on the left hand inner wing.
The air compressor provides system pressure. A
thermal switch is incorporated which cuts out
compressor operation at 120Ëš C. An air filter is fitted to
the compressor head. The filter is renewed every
40,000 kms. (24,000 miles).
Air dryer
The air dryer is connected into the air line between the
compressor and reservoir. It is mounted on the engine
air cleaner box. The dryer removes moisture from
pressurised air entering the system. All air exhausted
from the system passes through the dryer in the
opposite direction. The air dryer is regenerative in that
exhaust air absorbs moisture in the dryer and expels it
to atmosphere.
The air dryer is non-servicable, designed to last the
life of the vehicle. However, if any water is found in
the system, the air dryer must be replaced.
CAUTION: If the air dryer is removed from
the vehicle the ports must be plugged to
prevent moisture ingress.
Valve block
The valve block controls the direction of air flow. Air
flow to and from the air springs is controlled by seven
solenoid operated valves, one for each spring plus an
inlet, exhaust and outlet. In response to signals from
the ECU, the valves allow high pressure air to flow in
or out of the air springs according to the need to
increase or decrease pressure. A diaphragm valve
operated by the solenoid outlet valve ensures that all
exhausted air passes through the air dryer.
Mounted on the valve block is a pressure switch which
senses air pressure and signals the ECU to operate
the compressor when required.The compressor will
operate when the pressure falls between 7.2 and 8.0
bar. It will cut out at a rising pressure of between 9.5
and 10.5 bar.
The valve block contains the following serviceable
components: solenoid coils 1 to 6, drive pack and
pressure switch.
The valve block must only be dismantled after the
correct diagnosis procedure.
Reservoir
The 10 litre reservoir is mounted on the right hand
side of the chassis. One connection acts as air inlet
and outlet for the rest of the system. The reservoir
stores compressed air between set pressure levels.
The reservoir drain plug requires removing to check
for moisture in the system every 40,000 kms. (24,000
miles).
Height sensors
Four potentiometer type height sensors signal vehicle
height information to the ECU. The potentiometers are
mounted on the chassis and activated by links to the
front radius arms and rear trailing links. A height
sensor must be replaced in case of failure, and the
vehicle recalibrated using TestBook.
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FRONT SUSPENSION NEW RANGE ROVER
4
DESCRIPTION AND OPERATION
Air springs - front and rear
The air springs consist of the following components:
1. Top plate
2. Rolling rubber diaphragm
3. Piston
Front and rear air springs are of similar constuction
but are NOT interchangeable. The diaphragm is not
repairable, if failure occurs the complete air spring
must be replaced
Driver controls
Mounted in the centre of the dashboard, the driver
controls consist of an UP/DOWN switch, an INHIBIT
switch and a height setting indicator. For full
description.
See this section.
Relays, fuses
Located in the under bonnet fuse/relay box are 2
relays, plus 10, 20 and 30 amp fuses.
DRIVER CONTROLS
The driver controls are located in the centre of the
fascia. The controls consist of:
1. The HEIGHT CONTROL is a press and release
type rocker switch which is used to select the
required ride height. The vehicle will not respond
until switch is released. All movements selected
by operation of this switch are indicated by the
ride height indicator lights located next to the
switch.
2. The INHIBIT switch is a mechanically latching
switch. When selected it modifies the automatic
height changes of the system, for further details.
See Electrical Trouble Shooting Manual.
Selection of ’inhibit’ is indicated by illumination of
the switch tell-tale lamp, which is also bulb
tested with the ride height indicator.
3. High indicator light.
4. Standard indicator light.
5. Low indicator light.
6. Access indicator light.
7. Instrument pack warning light.
Indicator lights
When the ignition key is turned to position 2 all four
indicator lights, the air suspension warning light and
the inhibit switch will be illuminated continuously.
When the engine is started, the lights will remain
illuminated for 2 seconds, after which the current ride
height will be indicated. Two indicators will be
illuminated if the vehicle is between ride heights, with
the selected height flashing. When the new height is
achieved the indicator will be illuminated constantly
and the previous height indicator extinguished. The
inhibit switch indicator is illuminated while it is
activated. Both switches are illuminated with sidelights
switched on. Additional driver information is given by
the message centre in the instrument pack. For details
of the messages.
See this section.
Air suspension warning lamp
This amber lamp is located in the instrument pack.
The lamp will be constantly illuminated when driving at
high ride height and will flash when vehicle is at
extended height. The lamp will also illumunate if a
fault within the system is detected. A bulb check is
provided when the ignition switch is turned to position
2 and for 2 seconds after vehicle start.
ELECTRONIC AIR SUSPENSION
5
DESCRIPTION AND OPERATION
HEIGHT SETTINGS
Standard ride height
With the Inhibit switch off (unlatched), at speeds
below 80 km/h (50 mph) the standard ride height
indicator will be illuminated.
Standard vehicle ride height is maintained under all
load conditions. This also maintains headlamp
levelling.
Low ride height
Low ride height is automatically selected when the
vehicle speed exceeds 80 km/h (50 mph) for at least
30 seconds with the inhibit switch off. Low ride height
indicator lamp will flash during height change and
standard ride height indicator will extinguish when low
ride height is attained.
Standard ride height is automatically selected when
the vehicle speed drops below 56 km/h (35 mph) for
at least 30 seconds with the inhibit switch off.
The driver can select low ride height at any speed.
With the vehicle at low ride height, depressing the
inhibit switch (latched) will result in the vehicle
maintaining low ride height regardless of speed.
The height control switch can be used to change
between low and standard ride heights regardless of
speed.
Access mode
This position eases access to and from the vehicle.
With the vehicle stationary, doors and tailgate closed,
park brake applied, foot brake released and gearshift
in ’Park’ on automatic vehicles, press and release the
down switch. The vehicle will descend to access
mode. While the vehicle is descending, the access
indicator will flash. When access mode is attained, the
indicator will remain constantly illuminated, and
standard ride height lamp will be extinguished.
Access mode can be selected up to 40 seconds
before stopping vehicle. On stopping, applying the
handbrake, releasing the foot brake and selecting
’Park’ on automatic vehicles, the vehicle will lower to
access mode.
It is possible to select access up to 40 seconds after
switching engine off.
NOTE: Opening a door or tailgate will
immediately stop vehicle height change.
When the door is closed, the height
change will be completed. If the door is open for
more than thirty seconds, the system will need
’reminding’ of the new height when the door is
closed.
Driving the vehicle will result in vehicle rising
automatically to standard ride height. Alternatively
standard ride height can be achieved by closing all
doors, starting engine and pressing the up switch. The
standard indicator will flash during the change. When
standard ride height is attained the indicator will
remain constantly illuminated and access indicator will
be extinguished.
Crawl mode
In areas where height is restricted, the vehicle may be
driven in access mode. To achieve this, ensure the
inhibit switch is unlatched and select access mode.
When access height is achieved, press the inhibit
switch, the lamp will be illumunated. The message
centre in the instrument binnacle will beep three times
and display AIRSUS ISOLATED. The vehicle may
now be driven at speeds up to 32 km/h (20 mph).
If the vehicle is accelerated to 16 km/h (10 mph) the
message centre will beep three times and display
SLOW 20 MPH (32 KM/H) MAX.
If speed exceeds 40 km/h (25 mph) the vehicle will
rise to low profile, with low warning flashing. On
slowing to 32 km/h (20 mph) the vehicle will lower to
access mode with access warning illuminated.
When speed falls below 8 km/h (5 mph) the message
centre will beep three times and display AIRSUS
ISOLATED.
To cancel crawl mode, release the inhibit switch or
depress the up switch.
60
FRONT SUSPENSION NEW RANGE ROVER
6
DESCRIPTION AND OPERATION
High ride height
This position is used to improve approach and
departure angles and when wading. When at standard
ride height, pressing the up switch will select high ride
height provided the road speed is below 56 km/h (35
mph). The high ride height indicator will flash during
the height change. When the change is complete the
indicator will remain constantly illuminated, and
standard ride height indicator will be extinguished.
The indicator in the instrument pack will also be
illuminated. If speed exceeds 56 km/h (35 mph), the
vehicle will return to standard profile.
Extended ride height
This position is achieved if chassis is grounded
leaving wheel or wheels unsupported. Initial ECU
reaction is to lower (deflate) affected springs. After a
timed period the ECU detects no height change, it
therefore reinflates springs to extended profile in an
attempt to regain traction. The position will be held for
10 minutes, after which time the vehicle will
automatically return to standard ride height.
Pressing the down switch will lower vehicle 20 mm to
high profile.
If vehicle speed exceeds 56 km/h (35 mph) the
vehicle will immediately lower to standard ride height.
This speed could be achieved, for example, by
wheelspin.
VEHICLE TRANSPORTATION
New vehicles are transported from the factory with the
EAS system electronically ’frozen’ in access mode.
When road speed exceeds 40 km/h (25 mph), the
vehicle will rise to low ride height. It will return to
access mode if speed falls below 38.4 km/h (24 mph).
This condition is cancelled at pre-delivery inspection,
by entering the appropriate command via TestBook.
Vehicle transportation/recovery
CAUTION: When an air suspension vehicle
is secured to a transporter using the
chassis lashing eyes, there is a possibility
due to air leakage, self levelling or operation of
ride height controls that the tension of the
securing straps will be lost. To prevent this the
ride height should be set to access mode before
securing to transporter.
If the engine cannot be run and the vehicle is not in
access mode, the vehicle can be transported, but it
must be secured to the transporter by the roadwheels,
not the chassis.
ELECTRICAL TROUBLESHOOTING
For electrical details of the air suspension circuit.
See
Electrical Trouble Shooting Manual.
ELECTRONIC AIR SUSPENSION
7
DESCRIPTION AND OPERATION
SYSTEM OPERATION
Numbers refer to pneumatic circuit diagram
Air is drawn through the inlet filter (1) to the
compressor (2), where it is compressed to 10 æ 0,5
bar.
Compressed air passes to the air dryer (3) where
moisture is removed as it flows through the dryer
dessicant. The dessicant in the lower portion of the
dryer becomes wet.
Dried air passes through a non-return valve NRV1 to
the reservoir (4).
The 3 non-return valves (6) ensure correct air flow.
They also prevent loss of spring pressure if total loss
of reservoir pressure occurs.
The pressure switch (5) maintains system pressure
between set limits by switching on and off the
compressor via an ECU controlled relay.
For air to be admitted to an air spring (10), the inlet
valve (7) must be energised together with the relevant
air spring solenoid valve (9).
For air to be exhausted from an air spring, the exhaust
valve (8) must be energised together with the relevant
air spring solenoid valve.
The solenoid diaphragm valve (12) ensures that all air
exhausted to atmosphere passses through the dryer.
Exhausted air passes vertically downwards through
the dryer. This action purges moisture from the
dessicant and regenerates the air dryer.
Air is finally exhausted through the system air
operated diaphragm valve (13) and to atmosphere
through a silencer (14) mounted below the valve
block.
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FRONT SUSPENSION NEW RANGE ROVER
8
DESCRIPTION AND OPERATION
FRONT SUSPENSION
Description
The front suspension design on the New Range Rover
allows maximum wheel travel and axle articulation,
providing good ground clearance without loss of
traction or directional stability.
Near constant ride frequency under all load conditions
is achieved by utilizing advancements in suspension
geometry complemented to control and operation of
the air suspension system.
See this section.
Front axle suspension
1. Radius arms
2. Panhard rod
3. Shock absorbers
4. Bump stops
5. Anti-roll bar
6. Air springs
7. Front axle
ELECTRONIC AIR SUSPENSION
9
DESCRIPTION AND OPERATION
Long front radius arms (1) are fitted to the front axle
(7) and provide maximum axle articulation which is
vital for off road performance. The radius arm,
comprising a forged steel link with twin front
mountings using ferrule rubber bushes, is secured to
fabricated mounting brackets welded to the front axle.
Flexible rubber bushes are used on a stem end joint
to secure the rear of the radius arm to a mounting on
the chassis cross member as shown in 60M7040. The
vehicle height sensors are also linked to the front
radius arms; for full details of the height settings.
See
this section.
A panhard rod (2), which ensures that the axle
remains centrally located, is fitted transversely and
also uses ferrule rubber bush mountings at both axle
and chassis locations. An anti-roll bar (5) is fitted to
the front axle to control body roll and directional
stability. Two rubber bearing bushes, with retaining
straps, secure the anti-roll bar to the front axle, while
ball jointed links, suspended from the chassis, support
the rear of the anti-roll bar.
Conventional telescopic shock absorbers (3), used to
control body movement, are secured to fabricated
towers which are welded to the chassis. The upper
fixing uses a single retaining bolt passing through a
flexible rubber bush. The lower fixing of the shock
absorber comprises of a stem type mounting with two
flexible rubber bushes and support washers secured
to an axle mounting by a single retaining nut. Cellular
foam bump stops (4) are fitted under the chassis
adjacent to the air springs (6) and prevent possible
damage that could occur should there be excessive
axle to chassis movement. Should there be a loss of
air pressure in the air springs the vehicle can still be
driven safely at a speed not exeeding 35 mph (56kph)
with the bump stops resting on the axle, although this
will result in a hard ride. The loss of air pressure
should be investigated as soon as possible. The bump
stops are ’progressive’ and will reform from a
compressed state when the load is released.
SUPPLEMENTARY RESTRAINT SYSTEM
1
DESCRIPTION AND OPERATION
SYSTEM COMPONENTS - DISTRIBUTED SRS
SYSTEM
1. Airbag crash sensors
2. SRS warning light (airbag)
3. Rotary coupler
4. Driver’s airbag module
5. Passenger’s airbag module
6. Airbag diagnostic socket
7. Airbag diagnostic control unit
8. Airbag harness
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SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER
2
DESCRIPTION AND OPERATION
OPERATION
The airbag supplementary restraint system (SRS) is a
safety device which, when used in conjunction with
the seat belt, is designed to protect the driver and
front passenger by operating when the vehicle
receives a frontal impact (in the area shown)
exceeding a certain set speed.
In the event of a frontal impact, when the airbag
diagnostic control unit and one of the airbag crash
sensors senses the impact, the diagnostic control unit
triggers the airbag modules which fires an igniter. This
in turn ignites tablets of sodium azide which generate
a large amount of Nitrogen gas leading to airbag
inflation in approximately 30 milli-seconds.
When fully deployed the airbag offers additional
protection to the front seat occupant. As an occupant
moves into the airbag it immediately discharges the
gas from vent holes to provide progressive
deceleration and reduce risk of injuries. The whole
process is completed in approximately 0.3 seconds.
WARNING: All the airbag system
components, including the wiring harness,
MUST be renewed after the airbags have
deployed.
SRS warning light (airbag)
The warning light in the instrument pack illuminates
after the electrical circuits are switched on whilst a
system check is carried out. After about 7 seconds the
warning light will go out. The system checks the
airbag diagnostic control unit, airbag crash sensors
and the airbag harness.
In the event of a fault in the system the warning light
will lluminate and begin modulating. The airbag
diagnostic control unit logs the fault which can only be
accessed using TestBook .
SUPPLEMENTARY RESTRAINT SYSTEM
3
DESCRIPTION AND OPERATION
SYSTEM COMPONENTS - SINGLE POINT SENSED
SRS SYSTEM
1. SRS warning light (airbag)
2. Rotary coupler
3. Driver’s airbag module
4. Passenger’s airbag module
5. Airbag diagnostic socket
6. Airbag diagnostic control unit (DCU)
75
SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER
4
DESCRIPTION AND OPERATION
OPERATION
The airbag supplementary restraint system (SRS) is a
safety device which, when used in conjunction with
the seat belt, is designed to protect the driver and
front passenger in the event of a frontal collision.
The diagnostic control unit (DCU) is able to distinguish
between rough road conditions and a frontal collision.
If the DCU detects a frontal collision of sufficient
severity, it sends a fire signal to the airbag module
initiators. The initiators ignite tablets of sodium azide
which generate a large amount of Nitrogen gas
leading to airbag inflation in approximately 30
milli-seconds.
As the occupant moves into the fully inflated airbag,
the nitrogen gas discharges from vent holes in the
rear of the airbag. As the airbag deflates, it provide
progressive deceleration for the occupant and
reduces the risk of injuries. The process from airbag
initiation to deflation is completed in approximately 0.3
seconds.
WARNING: All the airbag system
components, including the wiring harness,
MUST be renewed after airbag
deployment.
SRS warning light
The airbag system carries out a system check every
time the ignition is switched to position 2. During the
system check, the instrument pack warning light is
illuminated to provide a bulb check. The warning lamp
is extinguished when the system check is complete,
after about 5 seconds.
If a system fault is found during the initial system
check or subsequently during driving, the warning light
will illuminate, indicating to the driver that there is a
fault with the airbag system. With the warning light on,
the airbag system will not operate in the event of a
frontal collision. The DCU records system faults in an
internal memory. The memory can be interrogated
using TestBook via the diagnostic socket located on
the passenger side fascia closing panel.
SUPPLEMENTARY RESTRAINT SYSTEM
1
PRECAUTIONS
GENERAL PRECAUTIONS
Making the system safe
Before commencing repair work on any airbag
components:
• Remove the key from the starter switch.
• Disconnect both battery leads, earth lead
first.
• Wait 10 minutes for DCU back-up power
circuit to discharge.
Care Points
WARNING: The airbag module contains
Sodium Azide which is poisonous and
extremely flammable. Contact with water,
acid or heavy metals may produce harmful or
explosive compounds. Do not dismantle,
incinerate or bring into contact with electricity.
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SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER
2
PRECAUTIONS
NEVER
• Drop any airbag system component.
NOTE: The airbag DCU is a shock
sensitive device and must be handled with
extreme care.
• Wrap arms around an airbag module.
• Attach anything to the airbag cover.
• Attempt to repair any component.
• Apply electrical power to a component
unless instructed to do so by an approved
test procedure.
• Transport airbag modules in the passenger
compartment of a car. Use the luggage
compartment.
• Install any airbag component that shows
signs of being dropped or improperly
handled, such as dents, cracks or
deformation.
• Install used airbag components from
another vehicle. When repairing an airbag
system, use only genuine new parts.
ALWAYS
• Carefully inspect any airbag component
before installation.
• Check airbag harness is correctly routed.
• Check airbag connectors are fully mated
and latched after completion of work.
Airbag handling and storage
• Do not try to dismantle the airbag module.
It has NO serviceable parts. Once an
airbag has been deployed, it cannot be
repaired or reused.
• Be careful that the airbag module receives
no strong shocks, it could deploy.
• Special bolts are necessary for installing
the airbag module. Do not use other bolts.
For temporary storage of the airbag module during
service, observe the following precautions.
• Always keep components dry.
• Always carry the airbag module with the
pad surface face up.
• Store the removed airbag module with the
pad surface face up.
• Do not allow anything to rest on the airbag
module.
• Place the airbag module in the designated
storage area.
SUPPLEMENTARY RESTRAINT SYSTEM
3
PRECAUTIONS
• If no designated storage area is available,
then the luggage compartment of the
vehicle should be used. Always lock the
luggage compartment when an airbag
module is stored in it and inform the
workshop supervisor.
WARNING: If the airbag module is
improperly stored face down, accidental
deployment could propel the unit with
enough force to cause serious injury.
• Store the removed airbag assembly on a
secure flat surface away from any electrical
equipment or high heat source (exceeding
85Ëš C/185Ëš F) and free of any oil, grease,
detergent of water.
CAUTION: Improper handling of storage
can internally damage the airbag module,
making it inoperative. If you suspect the
airbag module has been damaged, install a new
unit and refer to the Deployment/Disposal
Procedures for disposal of the damaged airbag.
Overnight storage
Airbag modules are classed as explosive devices and
as such must be stored in an approved secure steel
cabinet which has been registered by the local
authority.
CRASH SENSOR INSPECTION - DISTRIBUTED
SRS SYSTEM ONLY
1. After any degree of front body damage, inspect
both front crash sensors. Replace a sensor if
there are any signs of dents, cracks or
deformation.
2. Ensure the sensors are installed correctly. There
must be no gap between the sensor and body of
the vehicle. Use the fixing screws supplied with
the sensor and tighten to the correct torque.
Tighten front sensor fixing before rear sensor
fixing.
CAUTION: Take extra care when painting
or doing body work in the vicinity of the
sensors. Avoid direct exposure of the
sensors or harness to heat guns, welding or
spraying equipment.
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SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER
4
PRECAUTIONS
WIRING AND CONNECTORS
• Never attempt to modify, splice or repair
the airbag wiring. Never install electronic
equipment such as; a mobile telephone,
two-way radio or in-car entertainment
system in such a way that it interferes
electrically with the airbag wiring.
• Always ensure airbag wiring is routed
correctly. Be careful to avoid trapping or
pinching the airbag wiring. Look for
possible points of chaffing.
• Always use specified earth fixings
tightened to the correct torque. Poor
earthing can cause intermittent problems
that are difficult to diagnose.
• Ensure all airbag harness connectors are
mated correctly and securely fastened. Do
not leave the connectors hanging loose.
SUPPLEMENTARY RESTRAINT SYSTEM
5
PRECAUTIONS
WARNING LABELS
A combination of symbols/icons are displayed (either
in a suitable, prominent position or attached to the
component itself) to indicate:
• The need for caution when working in close
proximity to SRS components.
• The publication where suitable reference
and advice can be found (usually Repair
Manual or Owner’s Handbook).
NOTE: It is imperative that before any work
is undertaken on the SRS system that the
appropriate publication is read and
understood.
The following list indicates current locations for
warning lables. Exact positions may vary dependent
on legislation and market trends.
1. Bonnet locking platform. Refer to Owner’s
Handbook for information on the SRS system.
2. Driver’s and passenger’s sun visor. Refer to
Owner’s Handbook for information on the SRS
system.
3. End of fascia, passenger’s side (not all markets).
Do not use rear facing child seat in passenger
seat of vehicles fitted with passenger airbag.
4. Rotary coupler. Ensure wheels are positioned in
straight ahead position before removal and
refitting. Do not rotate mechanism. Refer to the
Repair Manual for information on the airbag
system.
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SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER
6
PRECAUTIONS
5. Airbag modules
A- Land Rover bar code. The code number(s) must be
recorded if the airbag module is to be replaced.
B- Warning, the use of gas generators is permitted
only for occupant restraint systems in vehicles fitted
with airbags. Not repairable. Handling is permitted
only by authorized personnel. Do not use any live
electrical test equipment. Do not open, remove or
install in another vehicle. Risk of malfunction and
personal injury. Upon deployment, an airbag unit
which is not properly mounted may become a
dangerous projectile. Refer to Repair Manual for
further instructions.
C- Danger Poison. Keep out of reach of children.
Contains sodium azide and sodium nitrate. Contents
are poisonous and extremely flammable. Contact with
acid or heavy metals may produce toxic gases.
VEHICLE RECOVERY
Towing - airbag not deployed
Normal towing procedures are unlikely to cause an
airbag to deploy. However, as a precaution, switch the
ignition off and then disconnect both battery leads.
Disconnect the negative lead first.
Towing - airbag deployed
Once the driver’s airbag has been deployed the
vehicle must have a front suspended tow. However,
as a precaution, switch the ignition off and then
disconnect both battery leads. Disconnect the
negative ’-’ lead first.
SUPPLEMENTARY RESTRAINT SYSTEM
7
PRECAUTIONS
AIRBAG MANUAL DEPLOYMENT
If a vehicle is to be scrapped and contains an
undeployed airbag module, the module must be
manually deployed. This operation should only be
carried out using the following recommended manual
deployment procedure.
Before deployment is started, the deployment tool self
test should be carried out.
Deployment tool SMD 4082/1 self test procedure
1. Insert blue and yellow connectors of tool lead
into corresponding sockets on face of tool.
2. Connect crocodile clips of second tool lead to
battery, red to positive and black to negative.
3. Red "READY" light should illuminate.
4. Press and hold both operating buttons.
5. Green "DEFECTIVE" light should illuminate.
6. Release both operating buttons.
7. Red "READY" light should illuminate.
8. Disconnect tool from battery.
9. Disconnect blue and yellow connectors from tool
face sockets.
10. Self test now complete.
Deployment with module fitted to vehicle
These guidelines are written to aid authorised
personnel to carry out the safe disposal of the airbag
module when fitted to the vehicle.
WARNING: Only use the Land Rover
approved deployment equipment. Deploy
airbag modules in a well ventilated,
designated area. Ensure airbag module is not
damaged or ruptured before deploying.
Driver’s airbag module
1. Carry out deployment tool self test.
2. Remove driver’s side fascia closing panel.
See
CHASSIS AND BODY, Repair.
3. Release airbag multiplug from fascia and
disconnect multiplug.
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SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER
8
PRECAUTIONS
WARNING: Ensure tool SMD 4082/1 is not
connected to battery.
4. Connect flylead SMD 4082/5 to airbag
connector.
5. Connect flylead SMD 4082/5 to tool SMD
4082/1.
WARNING: Ensure airbag module is
secure within steering wheel.
6. Connect tool SMD 4082/1 to battery.
WARNING: Ensure all personnel are
standing at least 15 metres away from
vehicle.
7. Press both operating buttons to deploy airbag
module.
8. DO NOT return to airbag module for 30 minutes.
9. Using gloves and face mask, remove airbag
module from steering wheel, place airbag
module in plastic bag and seal bag.
10. Transport deployed airbag module to designated
area for incineration.
NOTE: DO NOT transport airbag module in
the vehicle passenger compartment.
11. Scrap all remaining parts of airbag system. DO
NOT re-use or salvage any parts of the airbag
system, including steering wheel or steering
column.
SUPPLEMENTARY RESTRAINT SYSTEM
9
PRECAUTIONS
Passenger’s airbag module
1. Carry out deployment tool self test.
2. Remove glove box assembly.
See CHASSIS
AND BODY, Repair.
3. Release airbag connector from fascia and
disconnect multiplug.
WARNING: Ensure tool SMD 4982/1 is not
connected to battery.
4. Connect flylead SMD 4082/5 to harness
connector.
5. Connect flylead SMD 4082/5 to tool SMD
4082/1.
WARNING: Ensure airbag module is
secure within fascia.
6. Connect tool SMD 4082/1 to battery.
WARNING: Ensure all personnel are
standing at least 15 metres away from
vehicle.
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SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER
10
PRECAUTIONS
7. Press both operating buttons to deploy airbag
module.
8. DO NOT return to airbag module for 30 minutes.
9. Using gloves and face mask, remove airbag
module from fascia. Place airbag module in
plastic bag adn seal bag.
10. Transport deployed airbag module to designated
area for incineration.
NOTE: DO NOT transport airbag module in
the vehicle passenger compartment.
11. Scrap all remaining parts of airbag system. DO
NOT re-use or salvage any parts of the airbag
system.
Following the deployment of the airbags, the following
components must be replaced:
SRS wiring harness,
Airbag crash sensors (distributed system only),
Rotary coupler,
Driver’s airbag module,
Passenger’s airbag module,
Airbag diagnostic control unit,
Complete steering wheel assembly including
associated switches.
PRECAUTIONS
Dimensions ’A’ AND ’B’ on steering column must be
within tolerance.
Dimension ’A’ 3.0 - 4.0 mm
Dimension ’B’ 91.5 - 92.8 mm
If dimension ’A’ is incorrect replace steering column.
If dimension ’B’ is incorrect replace steering column,
and pedal box.
SUPPLEMENTARY RESTRAINT SYSTEM
11
PRECAUTIONS
Deployment with module removed from vehicle
These guidelines are written to aid authorised
personnel to carry out the safe disposal of airbag
modules when removed from the vehicle.
WARNING: Only use Land Rover approved
deployment equipment. Deploy airbag
modules in a well ventilated, designated
area.
Driver’s airbag module
1. Carry out deployment tool self test.
2. Remove airbag module from steering wheel.
See Repair.
3. Position tool SMD 4082/2 in vice, ensuring that
vice jaws grip tool above bottom flange to
prevent possibility of tool being forced upwards
from vice. Tighten vice.
4. Secure airbag module to tool SMD 4082/2.
Ensure module is correctly secured using both
fixings.
5. Ensure airbag module mounting brackets are
secure.
WARNING: Ensure tool SMD 4082/1 is not
connected to battery.
6. Connect flylead SMD 4082/4 to airbag module.
7. Connect flylead SMD 4082/4 to tool SMD
4082/1.
WARNING: Do not lean over module whilst
connecting.
8. Connect tool SMD 4082/1 to battery.
WARNING: Ensure all personnel are
standing at least 15 metres away from
module.
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SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER
12
PRECAUTIONS
9. Press both operating buttons to deploy airbag
module.
10. DO NOT return to airbag module for 30 minutes.
11. Using gloves and face mask, remove airbag
module from tool, place airbag module in plastic
bag and seal bag.
12. Wipe down tool with damp cloth.
13. Transport deployed airbag module to designated
area for incineration
NOTE: DO NOT transport airbag module in
the vehicle passenger compartment.
Passenger’s airbag module
1. Carry out deployment tool self test.
2. Remove airbag module from fascia.
See
Repair.
3. Position tool SMD 4082/6 in vice, ensuring that
vice jaws grip tool above bottom flange to
prevent possibility of tool being forced upwards
from vice. Tighten vice.
4. Position brackets SMD 4082/7 to tool; lightly
tighten bolts.
5. Secure airbag module to tool SMD 4082/6.
Ensure module is correctly secured using all
fixings.
SUPPLEMENTARY RESTRAINT SYSTEM
13
PRECAUTIONS
6. Ensure airbag module mounting brackets are
secure.
WARNING: Ensure tool SMD 4082/1 is not
connected to battery.
7. Connect flylead SMD 4082/5 to airbag module.
8. Connect flylead SMD 4082/5 to tool SMD
4082/1.
WARNING: Do not lean over module whilst
connecting.
9. Connect tool SMD 4082/1 to battery.
WARNING: Ensure all personnel are
standing at least 15 metres away from
module.
10. Press both operating buttons to deploy airbag
module.
11. DO NOT return to airbag module for 30 minutes.
12. Using gloves and face mask, remove airbag
module from tool, place airbag module in plastic
bag and seal bag.
13. Wipe down tool with damp cloth.
14. Transport deployed airbag module to designated
area for incineration
NOTE: DO NOT transport airbag module in
the vehicle passenger compartment.
SUPPLEMENTARY RESTRAINT SYSTEM
1
REPAIR
AIRBAG MODULE - PASSENGER SIDE
Service repair no - 76.73.69
WARNING: All the airbag system
components, including the wiring harness,
MUST be renewed after the airbags have
deployed.
Remove
1. Disconnect both battery terminals, disconnect
negative lead first.
2. Remove glove box assembly.
See CHASSIS
AND BODY, Repair.
3. Release and disconnect air bag module
multiplug.
4. Remove 4 bolts and washers (E-10 Torx Bit)
securing air bag module to fascia frame.
5. Carefully release and remove air bag module.
CAUTION: Store the airbag module
correctly.
See this section.
Refit
NOTE: If a new airbag module is being
fitted the serial numbers must be
recorded.
6. Carefully fit air bag module to fascia. Fit Torx
bolts, and washers.
7. Tighten bolts to
9 Nm. (7 lbf.ft)
8. Connect air bag module multiplug and secure to
location.
9. Fit glove box assembly.
See CHASSIS AND
BODY, Repair.
10. Connect battery terminals, fit battery cover and
secure with turnbuckles.
11. Check Supplementary Restraint System using
TestBook .
75
SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER
2
REPAIR
SRS ECU
Service repair no - 76.73.72
Remove
WARNING: Always disconnect negative
lead from battery first. Disconnection of
positive lead with negative lead connected
risks short circuit and severe sparking through
accidental grounding of spanner. Personal injury
could result.
1. Disconnect both battery terminals.
2. Remove centre console.
See CHASSIS AND
BODY, Repair.
3. Lift rear of sound deadener pad from
transmission tunnel.
4. Disconnect SRS ECU multiplug.
5. Release 2 multiplugs from bracket.
6. Remove 2 bolts securing ECU to bracket.
Remove ECU.
Refit
7. Reverse removal procedure.
SUPPLEMENTARY RESTRAINT SYSTEM
3
REPAIR
SRS HARNESS - SINGLE POINT SENSED SYSTEM
Service repair no - 76.73.73
The SRS harness is incorporated into the fascia
harness.
See ELECTRICAL, Repair.
SRS HARNESS - DISTRIBUTED SYSTEM
Service repair no - 76.73.73
Remove
1. Raise the vehicle.
WARNING: Support on safety stands.
2. Remove battery.
See ELECTRICAL, Repair.
3. Remove centre console.
See CHASSIS AND
BODY, Repair.
4. Remove passenger air bag module.
See this
section.
5. Remove radio.
See ELECTRICAL, Repair.
6. Remove instrument pack binnacle.
See
INSTRUMENTS, Repair.
7. Remove 5 screws securing switch pack to
fascia.
8. Disconnect switches, clock and temperature
sensor. Remove switch pack.
9. Remove 4 screws securing heater control panel.
10. Disconnect multiplugs. Remove control panel.
11. Release door aperture seal adjacent to A post
lower trim panels.
12. Driver’s side - LHD automatic vehicles only:
Remove 3 bolts securing foot rest. Remove foot
rest.
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SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER
4
REPAIR
13. Remove screw securing each A post lower trim
panel. Release panels from sprag clips. Remove
both trim panels.
14. Remove 4 scrivet fasteners securing drivers side
lower closing panel.
15. Disconnect footwell lamp multiplug. Remove
closing panel.
16. Disconnect SRS harness from main harness.
Release multiplug from clip.
17. Remove sound deadener pad from transmission
tunnel.
18. Disconnect multiplug from SRS ECU. Release 3
harness clips.
19. Remove both front wheel arch liners.
See
CHASSIS AND BODY, Repair.
SUPPLEMENTARY RESTRAINT SYSTEM
5
REPAIR
20. Remove 2 trim studs securing air cleaner baffle
beneath LH wheel arch. Remove baffle.
21. Disconnect both SRS crash sensor multiplugs.
22. Remove 4 bolts securing battery tray.
75
SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER
6
REPAIR
23. Remove 2 bolts securing air cleaner to valance.
24. Raise air cleaner and battery tray to gain access
to crash sensor harness clips.
25. Release clips securing each crash sensor
harness to valance.
26. Release harness grommets. Feed both
harnesses through valance into wheel arches.
27. Release 3 clips securing each crash sensor
harness to underside of wheel arches.
28. Release harness bulkhead grommets. Feed
harnesses through bulkhead into passenger
compartment.
29. Disconnect SRS multiplug from instrument pack.
SUPPLEMENTARY RESTRAINT SYSTEM
7
REPAIR
30. Disconnect drivers air bag module connector.
Release connector and harness from clips.
31. Release 13 clips securing SRS harness to fascia
frame.
NOTE: Due to restricted access, two outer
clips ’A’ securing harness above heater
unit may have to be cut. Ensure that
location holes are clear. Collect loose ends of
clips.
32. Release 3 clips securing fascia harness trunking
to passenger side fascia frame.
33. Remove nut securing lower end of each blower
assembly to fascia frame.
34. Route crash sensor ends of harness into
passenger air bag module space.
35. Feed SRS ECU connector into passenger air
bag module space.
36. Remove harness.
Refit
37. Position harness in passenger air bag module
space. Feed SRS ECU connector between
heater and fascia frame.
38. Route harness along transmission tunnel.
Secure harness clips.
39. Connect multiplug to ECU.
40. Fit sound deadener pad to transmission tunnel.
41. Route crash sensor ends of harness correctly
around fascia frame and behind blower
assemblies.
42. Secure harness clips to fascia frame.
43. Position fascia harness trunking. Secure with
clips.
44. Secure blower assemblies to fascia frame with
nuts.
45. Connect drivers air bag module, secure
multiplug and harness to trunking.
46. Connect SRS multiplug to instrument pack.
75
SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER
8
REPAIR
47. Route SRS crash sensor harnesses through
bulkhead into wheel arches, locate harness
grommets.
48. Secure harness clips beneath wheel arches.
49. Route harnesses through valances into engine
bay. Locate harness grommets.
50. Raise battery tray and air cleaner for access.
Route crash sensor harnesses. Secure harness
clips.
51. Connect multiplugs to crash sensors.
52. Secure battery tray and air cleaner with bolts.
53. Connect SRS harness multiplug to main
harness. Secure multiplug to bracket.
54. Fit air cleaner baffle beneath LH wheel arch.
Secure with trim studs.
55. Fit wheel arch liners.
See CHASSIS AND
BODY, Repair.
56. Position drivers side lower closing panel.
Connect footwell lamp multiplug.
57. Align closing panel. Secure with scrivet
fasteners.
58. Position ’A’ post lower trim panels. Engage
sprag clips. Secure with screws.
59. Re-fit door aperture seals.
60. LHD automatic vehicles only: Position foot
rest. Secure with bolts.
61. Position heater controls. Connect multiplugs.
Secure to fascia with screws.
62. Position fascia switch pack. Connect multiplugs.
Secure to fascia with screws.
63. Fit instrument pack binnacle.
See
INSTRUMENTS, Repair.
64. Fit radio.
See ELECTRICAL, Repair.
65. Fit passenger air bag module.
See this section.
66. Fit centre console.
See CHASSIS AND BODY,
Repair.
67. Fit battery.
See ELECTRICAL, Repair.
68. Remove safety stands. Lower vehicle.
SRS CRASH SENSOR
Service repair no - 76.73.70
Remove
WARNING: Always disconnect negative
lead from battery first. Disconnection of
positive lead with negative lead connected
risks short circuit and severe sparking through
accidental grounding of spanner. Personal injury
could result.
1. Disconnect both battery terminals.
2. Disconnect sensor multiplug.
3. Remove 2 bolts securing sensor to valance.
Remove sensor.
Refit
4. Reverse removal procedure.
SUPPLEMENTARY RESTRAINT SYSTEM
9
REPAIR
AIRBAG MODULE - DRIVER SIDE
Service repair no - 76.73.71
Remove
1. Disconnect both battery terminals, negative lead
first.
2. Remove steering column nacelle.
See
STEERING, Repair.
3. Disconnect Supplementary Restraint System
(SRS) ’shorting link’.
4. Unscrew 4 bolts (TX 30 Torx bit) securing
module to steering wheel.
NOTE: Fixings remain captive in steering
wheel.
NOTE: Rotate steering wheel for access to
all fixings.
5. Release module from steering wheel, disconnect
multiplug.
6. Remove module.
CAUTION: Store the airbag module
correctly.
See Description and operation.
Refit
NOTE: If a new airbag module is being
fitted, the serial numbers must be
recorded.
7. Position module and connect multiplug.
8. Tighten bolts to
9 Nm. (7 lbf.ft)
9. Connect SRS ’shorting link’and secure
connector to location.
10. Fit steering column nacelle.
See STEERING,
Repair.
11. Connect battery terminals, positive before
negative. Fit and secure battery cover.
12. Check SRS using TestBook .
CHASSIS AND BODY
1
ADJUSTMENT
FRONT DOOR
Service repair no - 76.28.07
NOTE: Adjustment should not be
necessary unless door or hinges have
been renewed.
Alignment of door to aperture.
1. Gain access to ’A’ post hinge bolts by removing
relevant wheel arch liner.
See Repair.
2. Slacken 2 bolts securing striker to ’B/C’ post.
3. Slacken 6 bolts securing door hinges to ’A’ post.
4. With assistance, adjust door position in aperture.
Tighten hinge bolts to
30 Nm. (22 lbf.ft)
Profile adjustment, door skin/frame to adjacent
body panels.
5. Slacken 4 bolts securing hinges to door.
6. With assistance adjust inboard/outboard position
of door. Tighten hinge bolts to
30 Nm. (22 lbf.ft)
CAUTION: Ensure that leading edge of
door is flush with adjacent panels or wind
noise will result.
7. When alignment of door is correct, adjust height
and inboard/outboard position of striker. Tighten
striker bolts. Check for correct door latching.
8. Slacken bolts and readjust striker position as
necessary. Tighten striker bolts to
22 Nm. (16
lbf.ft)
9. Fit wheel arch liner.
See Repair.
REAR DOOR
Service repair no - 76.28.08
NOTE: Adjustment should not be
necessary unless door or hinges have
been renewed.
1. Open door and slacken 2 bolts securing striker
to ’D’ post.
2. Open front door and slacken 6 bolts securing
rear door hinges to ’B/C’ post.
3. With assistance, adjust door position in aperture
and tighten hinge bolts to
25 Nm. (18 lbf.ft)
4. To adjust profile of door skin and frame relative
to adjacent body panels, slacken 4 bolts
securing hingess to door.
5. With assistance adjust inboard/outboard position
of door. Tighten hinge bolts to
25 Nm. (18 lbf.ft)
CAUTION: Ensure that leading edge of
door is flush with adjacent panels or wind
noise will result.
6. When alignment of door is correct, adjust height
and inboard/outboard position of striker. Tighten
striker bolts and check for correct door latching.
7. Slacken bolts and readjust striker position as
necessary. Tighten striker bolts to
22 Nm. (16
lbf.ft)
CHASSIS AND BODY
1
REPAIR
BONNET
Service repair no - 76.16.01
Remove
1. Open bonnet.
2. Mark hinge outlines on bonnet.
3. Remove 2 hinge bolts from each side.
4. Disconnect washer tube at T piece on bonnet,
release tube from clip.
5. With assistance, release bonnet support struts at
lower ends.
6. With assistance, remove 2 remaining hinge bolts
and remove bonnet.
Refit
7. With assistance, fit bonnet. Fit, but do not tighten
bolts.
8. With assistance, connect bonnet support struts.
9. Connect washer tube, secure to clip.
10. Close bonnet, check alignment.
11. Open bonnet, tighten hinge bolts.
12. Close bonnet.
76
CHASSIS AND BODY NEW RANGE ROVER
2
REPAIR
BONNET LOCK PIN
Service repair no - 76.16.24
Remove
1. Remove bolts securing lock pin to bonnet.
2. Remove pin.
Refit
3. Position lock pin to bonnet.
4. Fit bolts but do not tighten.
5. Close and open bonnet to align pin.
6. Secure pin with bolts.
7. Lubricate pin.
BONNET LOCK - LEFT HAND
Service repair no - 76.16.21
Remove
1. Remove bolts securing bonnet lock.
2. Release outer and inner cables from lock.
3. Remove lock.
Refit
4. Reverse removal procedure.
CHASSIS AND BODY
3
REPAIR
BONNET LOCK - RIGHT HAND
Service repair no - 76.16.25
Remove
1. Release 3 turnbuckles securing battery cover.
Remove cover
2. Remove 2 bolts securing bonnet lock to platform.
3. Manoeuvre lock and disconnect alarm switch
multiplug.
4. Release inner and outer cables from lock.
5. Remove lock.
Refit
6. Reverse removal procedure.
76
CHASSIS AND BODY NEW RANGE ROVER
4
REPAIR
BONNET SAFETY CATCH
Service repair no - 76.16.34
Remove
1. Remove bolts securing safety catch to bonnet.
2. Remove safety catch.
Refit
3. Position catch to bonnet.
4. Fit bolts, do not tighten.
5. Close and open bonnet to align catch.
6. Secure catch with bolts.
BONNET STRUT
Service repair no - 76.16.14
Remove
1. Support bonnet in open position.
2. Release clip securing strut lower ball joint.
3. Remove screws securing strut bracket to bonnet.
4. Remove strut and bracket.
5. Remove strut from bracket.
Refit
6. Fit strut to bonnet bracket, fit to bonnet.
7. Secure strut to lower ball joint.
8. Fit bracket screws. Remove support, close
bonnet.
CHASSIS AND BODY
5
REPAIR
CENTRE CONSOLE
Service repair no - 76.25.01
Remove
1. Remove electric window switch pack.
See
ELECTRICAL, Repair.
2. Disconnect rear footwell lamp multiplug.
3. Remove base in console bin.
4. Remove nuts securing rear of console to floor
studs.
5. Move both front seats fully rearward.
6. Remove 2 screws securing each side panel to
centre console. Release sprag clips from fascia
switch pack by firmly pulling rearwards. Remove
side panels.
7. Remove screw at rear of gear lever applique.
Raise rear end of applique to disengage 2 spring
clips at forward end.
8. Disconnect cigar lighter multiplug, release cigar
lighter bulb. Remove gear lever applique.
9. Manual gearbox models:
Remove gear knob. Remove 2 bolts securing
front of console to floor.
10. Automatic gearbox models:
Remove 2 screws securing selector lever.
11. Remove selector lever.
76
CHASSIS AND BODY NEW RANGE ROVER
6
REPAIR
12. Remove 3 screws securing selector graphics
plate.
13. Raise selector graphics plate, disconnect
multiplug.
14. Remove selector graphics plate.
15. All models:
Remove clip securing park brake lever clevis pin,
remove clevis pin. Raise park brake lever to
vertical position.
16. Raise rear of console to disengage rear vent
ducts. Remove centre console.
Refit
17. Fit centre console, ensuring that ducts to rear
fresh air vents are correctly engaged.
18. Fit nuts securing centre console to floor.
19. Automatic - position graphics plate over selector
lever, connect multiplug.
20. Align graphics plate to console, secure with
screws.
21. Fit selector lever, secure with screws.
22. Manual - secure front of centre console to floor
with bolts.
23. Fit gear knob.
24. Lower park brake lever, fit clevis pin and secure
pin with clip.
25. Position gear/selector lever applique, connect
cigar lighter multiplug and insert illumination bulb
in holder.
26. Engage applique clips to console. Secure
applique with screw.
27. Position console side panels. Firmly push
forward to engage sprag clips into fascia switch
pack. Fit and tighten screws.
28. Return front seats to original positions.
29. Fit base to console bin, tighten with screws.
30. Connect rear footwell lamp multiplug.
31. Fit electric window switch pack.
See
ELECTRICAL, Repair.
CHASSIS AND BODY
7
REPAIR
CHASSIS CROSS MEMBER
Remove
1. Disconnect battery negative lead.
2. Raise vehicle on four post lift.
3. Support transmission with a suitable stand.
4. Remove and discard 6 nuts securing
transmission mount to crossmember. Remove
snubber bar.
5. Remove 3 of 4 nuts and bolts securing each side
of crossmember to chassis.
6. With assistance, remove remaining bolt securing
crossmember. Remove crossmember.
Refit
7. With assistance, position crossmember to
chassis. Secure with nuts and bolts. Tighten to
45 Nm. (33 lbf.ft)
8. Fit snubber bar. Secure transmission mount to
crossmember with new flange nuts. Tighten to
45 Nm. (33 lbf.ft)
9. Remove support from transmission.
10. Lower vehicle.
11. Reconnect battery negative lead.
76
CHASSIS AND BODY NEW RANGE ROVER
8
REPAIR
ENGINE ACOUSTIC COVER
Service repair no - 76.11.06
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Release 4 threaded fasteners securing engine
acoustic cover to chassis brackets.
3. Release acoustic cover from brackets and
manoeuvre past steering gear.
Refit
4. Fit acoustic cover to brackets and secure with
threaded fasteners.
GEARBOX LOWER ACOUSTIC COVER
Service repair no - 76.11.13
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Release 6 threaded fasteners securing lower
acoustic cover to side acoustic covers.
3. Remove lower acoustic cover.
Refit
4. Fit acoustic cover to side acoustic covers.
5. Tighten threaded fasteners securing lower cover
to side covers.
6. Remove stand(s) and lower vehicle.
CHASSIS AND BODY
9
REPAIR
GEARBOX ACOUSTIC COVER - RH
Service repair no - 76.11.14
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove gearbox lower acoustic cover.
See this
section.
3. Remove bolt securing RH acoustic cover to
crossmember.
4. Remove bolt securing RH acoustic cover to
chassis member.
5. Remove gearbox RH acoustic cover.
Refit
6. Fit acoustic cover to chassis and secure with
bolts.
7. Fit gearbox lower acoustic cover.
See this
section.
GEARBOX ACOUSTIC COVER - LH
Service repair no - 76.11.15
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove gearbox lower acoustic cover.
See this
section.
3. Remove bolt securing LH acoustic cover to
crossmember.
4. Remove bolt securing LH acoustic cover to
chassis member.
5. Remove gearbox LH acoustic cover.
Refit
6. Fit acoustic cover to chassis and secure with
bolts.
7. Fit gearbox lower acoustic cover.
See this
section.
76
CHASSIS AND BODY NEW RANGE ROVER
10
REPAIR
FRONT BUMPER VALANCE
Service repair no - 76.22.72
Remove
1. Raise the vehicle.
WARNING: Support on safety stands.
2. Remove battery cover for access to RH fog
lamp.
3. Disconnect fog lamp multiplugs and breather
hoses.
4. Release 2 clips securing bumper ends to
mounting brackets.
CAUTION: Loosen bolts securing bumper
end mounting brackets to chassis frame to
avoid damage to sealing rubber during
bumper remove and refit.
CHASSIS AND BODY
11
REPAIR
5. Remove 2 bumper bolt access plugs from
bumper valance. Remove bolts.
6. With assistance remove bumper assembly.
Do
not carry out further dismantling if
component is removed for access only.
7. Remove 8 studs and 6 clips securing extensions
spoiler. Remove extension.
8. Remove 8 screws securing fog lamps. Remove
lamps.
9. Remove 8 bolts securing bumper end brackets
to bumper. Remove brackets.
WARNING: If front bumper is damaged due
to impact, the impact cans must be
inspected. There must be no visible
deformation. The overall length must be 188.25
mm æ 0.5 mm. Replace the impact cans if
necessary.
Refit
10. Fit end brackets and secure with bolts. Fit fog
lamps and secure with screws.
11. Fit extension and secure with clips and studs.
12. With assistance fit bumper assembly, tighten
bolts to
70Nm. (52 lbf.ft)
13. Fit bolt access plugs.
14. Align end brackets, tighten bolts and secure
bumper end clips.
15. Connect fog lamp multiplugs and breather
hoses, fit battery cover.
16. Remove safety stands. Lower vehicle.
76
CHASSIS AND BODY NEW RANGE ROVER
12
REPAIR
EXTENSION SPOILER FRONT BUMPER
Service repair no - 76.22.78
Remove
1. Raise the vehicle.
WARNING: Support on safety stands.
2. Remove 8 studs and 6 clips securing spoiler to
front bumper.
3. Remove spoiler halves.
Refit
4. Fit spoiler halves to bumper. Secure with clips
and studs.
5. Remove safety stands. Lower vehicle.
REAR BUMPER VALANCE
Service repair no - 76.22.74
Remove
1. Raise the vehicle.
WARNING: Support on safety stands.
2. Remove rear road wheels.
3. Remove 3 screws securing each mud flap.
Remove mud flaps.
4. Remove 2 screws securing each wheel arch
liner extension panel to rear bumper/chassis.
5. Remove 2 wheel arch liner extension panels.
6. Release 2 clips securing bumper ends to
mounting brackets.
CHASSIS AND BODY
13
REPAIR
7. Disconnect 3 towing harness multiplugs.
8. Remove 2 mounting bolt covers.
9. Remove 2 bolts securing bumper to chassis.
10. With assistance, release bumper ends from
brackets. Remove bumper.
Refit
11. With assistance, position bumper. Engage nylon
end supports to brackets.
12. If necessary, slacken bolts securing end support
brackets. Align bumper to body. Tighten to
29
Nm. (22 lbf.ft)
13. Fit bumper mounting bolts. Tighten to
70 Nm.
(52 lbf.ft)
14. Fit bolt covers.
15. Secure bumper end clips.
16. Connect towing harness multiplugs.
17. Position wheel arch liner extensions. Secure with
screws.
18. Position mud flaps. Secure with screws.
19. Fit road wheels. Tighten to
108 Nm. (80 lbf.ft)
20. Remove safety stands. Lower vehicle.
FASCIA ASSEMBLY
Service repair no - 76.46.23/99
WARNING: The fascia assembly houses
the heater distribution unit, blower
assemblies and air conditioning
evaporator. Assistance is essential during
removal and refit procedures.
CAUTION: When removed from the
vehicle, the fascia should be placed on a
soft covered work surface, supported on
suitable wooden blocks.
Remove
1. Vehicles with SRS only: Remove battery.
See
ELECTRICAL, Repair.
2. Vehicles without SRS: Disconnect battery
negative lead.
3. Drain cooling system.
See COOLING SYSTEM,
Repair.
4. Loosen hose clips, disconnect hoses from
heater pipes.
5. Remove centre console.
See this section.
6. Remove steering column.
See STEERING,
Repair.
7. Remove wiper motor and linkage.
See WIPERS
AND WASHERS, Repair.
8. Disconnect passenger side heated front screen
multiplug. Release multiplug from clip.
76
CHASSIS AND BODY NEW RANGE ROVER
14
REPAIR
9. Remove 6 bolts, remove remaining scuttle side
panel.
10. Remove heater intake pollen filters.
11. Remove 8 screws securing each pollen filter
housing. Remove both housings.
12. Remove radio.
See ELECTRICAL, Repair.
13. Release door aperture seal adjacent to ’A’ post
lower trim panels.
14. Driver’s side - LHD automatic vehicles only:
Remove 3 bolts securing foot rest through ’A’
post lower trim, remove foot rest.
15. Remove screw securing each ’A’ post lower trim
panel, release from single sprag clip, remove
both trim panels.
CHASSIS AND BODY
15
REPAIR
16. Remove fuse cover from driver’s seat base trim.
17. Remove screw and 2 trim studs, remove seat
base trim.
18. Release 4 sprag clips, remove driver’s side
carpet retainer.
19. Remove 2 scrivet fasteners securing lower
closing panel to passenger side of fascia.
20. Release closing panel, disconnect footwell lamp,
release diagnostic multiplug. Remove closing
panel.
21. Remove 4 bolts, remove fascia centre bracket.
76
CHASSIS AND BODY NEW RANGE ROVER
16
REPAIR
22. Disconnect 4 multiplugs from Body Electrical
Control Module (BeCM)
23. Remove captive nut, remove earth wires from
stud at base of driver’s side ’A’ post.
24. Disconnect multiplugs at base of each ’A’ post.
25. Release BeCM harness from sill, route into
fascia to prevent fouling as fascia is removed.
26. Disconnect multiplugs and release vacuum hose
from brake and clutch switches.
27. Models with SRS only: Disconnect SRS
multiplug from main harness.
CHASSIS AND BODY
17
REPAIR
28. Disconnect multiplug from SRS control module,
route harness into fascia to prevent fouling as
fascia is removed.
29. Remove both front wheel arch liners.
See this
section.
30. Remove 2 scrivet fasteners securing air cleaner
baffle beneath LH wheel arch. Remove baffle.
31. Disconnect both SRS crash sensor multiplugs.
32. Remove 4 bolts securing battery tray and 2 bolts
securing air cleaner to valance.
76
CHASSIS AND BODY NEW RANGE ROVER
18
REPAIR
33. Raise air cleaner and battery tray for access to
crash sensor harness clips.
34. Release clips securing each crash sensor
harness to valance. Release harness grommets
and feed both harnesses through valance into
wheel arches.
35. Release 3 clips securing each crash sensor
harness to underside of wheel arches.
36. Release harness grommets, feed harnesses
through bulkhead and route into fascia to
prevent fouling as fascia is removed.
37. Vehicles with air conditioning only: Discharge
air conditioning system.
See AIR
CONDITIONING, Adjustment.
38. Remove bolt securing pipe clamp to
Thermostatic Expansion Valve (TXV).
39. Release pipes from TXV and remove ’O’ rings.
Seal pipes and ports of TXV.
40. All models: Remove 4 tube bolts securing
fascia to scuttle panel.
CHASSIS AND BODY
19
REPAIR
41. Remove nuts and washers securing fascia to
base of ’A’ posts.
42. Remove bolt securing fascia to pedal box.
43. Using assistance, carefully manoeuvre the
fascia through the driver’s door aperture. Place
fascia on a soft covered work surface, supported
on suitable wooden blocks.
44. Remove rubber seals from air intake ducts.
45. Collect rear heater duct connecting tubes.
Refit
46. Fit intake seals to blower motor ducts. Tape
rubbers inside blower ducts to aid fitment.
NOTE: Tape the rubbers at this stage, as
they are almost impossible to locate after
dash fitment.
47. Fit guide pins LRT-76-001 to outer fascia studs.
48. With assistance, manoeuvre fascia into position
through driver’s front door aperture. Locate
guide pins.
NOTE: Assistance from a third person may
be necessary when guiding heater pipes
through bulkead.
49. Loosely fit 1 tube bolt, fascia to scuttle.
50. Fit bolt securing fascia to pedal box. Tighten to
25 Nm. (18 lbf.ft)
51. Fit nuts and washers at base of A posts. Tighten
to
25 Nm. (18 lbf.ft)
52. Remove guide pins.
53. Fit remaining tube bolts. Tighten to
25 Nm. (18
lbf.ft)
54. Fit rear heater duct connecting pipes.
55. Remove tape from intake seals.
56. Engage lips of sealing rubbers around scuttle
apertures.
57. Fit pollen filter housings, tighten bolts.
58. Fit scuttle side panel to passenger side of
vehicle, tighten bolts.
59. Connect heated screen multiplug, fit to side
panel clip.
60. Connect hoses to heater pipes. Tighten clips.
61. Air conditioning vehicles: Remove seals from
air conditioning pipes and TXV ports.
62. Lubricate new O rings with clean compressor oil,
fit to pipes.
63. Locate pipes in TXV ports, position clamp and fit
clamp bolt.
64. Engage evaporator drain tubes over pipes in
transmission tunnel.
65. Vehicles with SRS only: Route SRS crash
sensor harnesses through bulkhead into wheel
arches, locate harness grommets.
66. Secure harness clips beneath wheel arches,
route harnesses through valances into engine
bay, locate harness grommets.
67. Raise battery tray and air cleaner for access.
Route crash sensor harnesses, secure harness
clips, connect multiplugs to crash sensors.
68. Tighten battery tray and air cleaner bolts.
69. Connect multiplug to SRS control module.
70. Connect SRS harness multiplug to main
harness.
71. Fit air cleaner baffle beneath LH wheel arch,
secure with scrivet fasteners.
72. Fit wheel arch liners.
See this section.
73. All models:Route harness along sill, connect
multiplugs to BeCM.
74. Connect multiplugs at base of ’A’ posts and
secure plugs to brackets.
75. Fit earth wires to stud, tighten captive nut.
76. Connect vacuum hose and multiplugs to brake
and clutch pedal switches.
77. Position closing panel beneath passenger side
of fascia. Secure dianostic plug, connect footwell
lamp. Align closing panel, secure with scrivet
fasteners.
78. Fit carpet retainer, engage sprag clips.
79. Fit seat base trim panel, secure trim studs,
tighten screw.
80. Fit fuse cover to seat base trim.
81. Fit both ’A’ post lower trim panels, secure sprag
clips. Engage door aperture seals.
76
CHASSIS AND BODY NEW RANGE ROVER
20
REPAIR
82. LHD automatic vehicles only: Fit foot rest,
secure with bolts.
83. Fit radio.
See ELECTRICAL, Repair.
84. Fit wiper motor and linkage.
See WIPERS AND
WASHERS, Repair.
85. Fit steering column.
See STEERING, Repair.
86. Fit centre console.
See this section.
87. Refill cooling system.
See COOLING SYSTEM,
Repair.
88. Vehicles with SRS only: Fit battery.
See
ELECTRICAL, Repair.
89. Reconnect battery negative lead.
90. Evacuate and recharge air conditioning.
See
AIR CONDITIONING, Adjustment.
FASCIA ASSEMBLY - VEHICLES WITH SINGLE
POINT SENSED SRS
Service repair no - 76.46.23/99
WARNING: Refer to SRS safety
precautions before commencing repair.
WARNING: The fascia assembly houses
the heater distribution unit, blower
assemblies and air conditioning
evaporator and is therefore heavy. Assistance is
essential during removal and refit procedures.
CAUTION: When removed from the
vehicle, the fascia should be placed on a
work surface with a soft covering and
supported on suitable wooden blocks.
Remove
1. Remove key from starter switch and wait 10
minutes for SRS back up power circuit to
discharge.
2. Disconnect both battery terminals, earth lead
first.
3. Drain cooling system.
See COOLING SYSTEM,
Repair.
4. Release 2 clips securing heater hoses to heater
matrix and disconnect hoses.
5. Cap both heater matrix pipes to prevent coolant
spillage inside vehicle during fascia removal.
6. Recover refrigerant from air conditioning system.
See AIR CONDITIONING, Adjustment.
CHASSIS AND BODY
21
REPAIR
7. Remove bolt securing pipe clamp to thermostatic
expansion valve (TXV) and release pipes.
8. Remove and discard ’O’ ring seals from air
conditioning pipes.
9. Immediately cap both air conditioning pipes and
TXV ports to prevent moisture entering the air
conditioning system.
10. Remove wiper motor and linkage.
See WIPERS
AND WASHERS, Repair.
11. Disconnect passenger side heated screen
multiplug.
12. Release heated screen multiplug from scuttle
side panel and position aside.
13. Remove 6 bolts securing scuttle side panel to
scuttle and remove panel.
14. Remove pollen filter from both heater intake
housings.
15. Remove 8 screws securing each heater intake
housing to scuttle and remove intake housings.
Release sealing rubbers from scuttle panel
aperture.
16. Remove centre console.
See this section.
17. Remove transmission tunnel insulation pad.
76
CHASSIS AND BODY NEW RANGE ROVER
22
REPAIR
18. Release latching mechanism and disconnect
multiplug from airbag diagnostic and control unit
(DCU).
19. Release SRS harness from transmission tunnel
and position to fascia to avoid snagging.
20. Remove 6 nuts securing gear lever gaiter ring to
transmission tunnel and release gaiter.
21. Remove 2 bolts securing gear lever to gearbox
remote and remove gear lever.
22. Disconnect high/low switch multiplug.
23. Remove 4 bolts securing fascia centre bracket to
fascia and transmission tunnel.
24. Remove fascia centre bracket.
25. Remove radio.
See ELECTRICAL, Repair.
26. Remove steering column.
See STEERING,
Repair.
CHASSIS AND BODY
23
REPAIR
27. Remove 3 scrivets securing lower fascia closing
panel to passenger’s side of fascia.
28. Release closing panel and release diagnostic
connector from panel.
29. Release door aperture seal adjacent to ’A’ post
lower trim panels.
30. Remove screw securing each ’A’ post lower trim
panel to ’A’ post.
31. Release ’A’ post lower trim panels from sprag
clip and remove panels.
32. Remove fuse box cover from driver’s seat base
trim.
33. Remove screw and 3 trim studs securing seat
base trim to body and remove seat base trim.
34. Release 4 sprag clips securing driver’s side
carpet retainer to body and remove carpet
retainer.
35. Disconnect 3 multiplugs from Body Electrical
Control Module (BeCM).
36. Position carpet aside and disconnect multiplug
from rear of BeCM.
76
CHASSIS AND BODY NEW RANGE ROVER
24
REPAIR
37. Remove captive nut securing earth wires to
driver’s side lower ’A’ post and release 3
additional earth wires.
38. Disconnect 3 multiplugs at base of driver’s side
’A’ post.
39. Release harness from driver’s side carpet and
position to fascia to avoid snagging.
40. Disconnect multiplugs from clutch and 2 brake
pedal switches.
41. Disconnect vacuum hose from clutch and brake
pedal switches.
42. Disconnect 2 multiplugs at base of passenger’s
side ’A’ post.
43. Remove 2 nuts securing fascia to ’A’ post and
transmission tunnel bracket, passenger’s side
44. Remove 2 nuts securing fascia to ’A’ post and
transmission tunnel bracket, driver’s side.
CHASSIS AND BODY
25
REPAIR
45. Remove 4 tube bolts securing fascia assembly
to scuttle panel.
46. Disconnect 2 evaporator drain hoses from
evaporator.
47. Using assistance, carefully manoeuvre fascia
assembly through the driver’s door aperture.
Position the fascia on a work surface with a soft
covering and support on suitable wooden blocks.
48. Collect 2 ducts connecting rear heating pipes to
fascia assembly.
Refit
49. Tape intake duct seals inside blower duct to aid
fitment.
50. Fit guide pins LRT-76-001 to outer fascia studs.
51. With assistance, manoeuvre fascia assembly
through driver’s door aperture and locate guide
pins to scuttle panel.
NOTE: Assistance from a third person may
be required to guide heater pipes through
bulkhead.
52. Fit one tube bolt securing fascia to scuttle panel
but do not tighten.
53. Fit nuts securing fascia to lower ’A’ posts and
tighten to
25 Nm. (18 lbf.ft)
54. Fit nuts securing fascia to transmission tunnel
brackets and tighten to
25 Nm. (18 lbf.ft)
55. Remove LRT-76-001.
56. Fit remaining tube bolts securing fascia to scuttle
panel and tighten to
25 Nm. (18 lbf.ft)
57. Fit fascia centre bracket, fit bolts and tighten to
25 Nm. (18 lbf.ft)
58. Connect evaporator drain hoses to evaporator.
59. Fit ducts connecting rear heating pipes to fascia
assembly.
60. Fit gearlever to gearbox remote, fit bolts and
tighten to
25 Nm. (18 lbf.ft)
61. Fit gear lever gaiter and ring to transmission
tunnel and secure with nuts.
62. Connect high/low switch multiplug.
63. Position SRS harness to transmission tunnel.
64. Connect multiplug to airbag DCU. Ensure
connector latching mechanism is correctly
engaged.
65. Fit transmission tunnel insulation pad to
transmission tunnel and position multiplugs
through pad.
66. Fit radio.
See ELECTRICAL, Repair.
67. Connect multiplugs at base of passenger’s side
’A’ post.
68. Fit passenger’s side ’A’ post lower trim panel
and secure with screw.
69. Engage door aperture seal to door aperture.
70. Position fascia lower closing panel and engage
diagnostic connector to panel.
71. Position closing panel to fascia and secure with
scrivets.
72. Connect vacuum hose to clutch and brake pedal
switches.
73. Connect multiplugs to clutch and brake pedal
switches.
74. Position harness to driver’s side carpet.
75. Connect multiplugs to BeCM.
76. Connect multiplugs at base to driver’s side ’A’
post.
77. Position earth wires to ’A’ post stud, fit and
secure captive nut.
78. Fit driver’s side carpet retainer and engage to
clips.
79. Fit seat base trim and secure with trim studs and
screw.
80. Fit seat base fuse box cover.
81. Fit driver’s side lower ’A’ post trim and secure
with screw.
82. Fit steering column.
See STEERING, Repair.
83. Fit radio.
See ELECTRICAL, Repair.
84. Fit centre console.
See this section.
85. Remove tape from heater intake ducts.
86. Engage heater intake seals to scuttle apertures.
87. Fit heater intake housings and secure with
screws.
88. Fit pollen filters to intake housings.
76
CHASSIS AND BODY NEW RANGE ROVER
26
REPAIR
89. Fit wiper motor and linkage.
See WIPERS AND
WASHERS, Repair.
90. Fit scuttle side panel to scuttle and secure with
bolts.
91. Connect heated screen multiplug and engage
multiplug to scuttle side panel bracket.
92. Remove caps from heater matrix pipes.
93. Engage heater matrix grommet to bulkhead
aperture.
94. Connect heater hoses to heater matrix and
secure with clips.
95. Remove caps from air conditioning pipes and
TXV.
96. Lubricate NEW ’O’ ring seals with clean
compressor oil and fit to air conditioning pipes.
97. Connect air conditioning pipes to TXV, position
clamp and fit bolt.
98. Tighten clamp bolt to
6 Nm. (4 lbf.ft)
99. Charge air conditioning system.
See AIR
CONDITIONING, Adjustment.
100. Fill coolant system.
See COOLING SYSTEM,
Repair.
101. Connect both battery terminals, earth lead last.
FASCIA CLOSING PANEL
Service repair no - 76.46.27
Remove
1. Remove closing panel screw covers and screws.
2. Lower closing panel.
3. Disconnect air tube from closing panel, remove
panel.
Refit
4. Reverse removal procedure.
CHASSIS AND BODY
27
REPAIR
FRONT DOOR ASSEMBLY
Service repair no - 76.28.01/99
Remove
1. Release door harness protective sleeve from ’A’
post.
2. Disconnect door harness multiplugs.
3. Remove door check strap retaining pin.
CAUTION: Apply protective tape to ’A’
post before drifting out retaining pin.
4. Remove door hinge pin retaining clips.
5. With assistance, remove door assembly.
Refit
6. With assistance, position door on hinges. Fit
retaining clips.
7. Align door check strap. Fit retaining pin.
8. Remove protective tape from ’A’ post.
9. Connect harness multiplugs. Secure protective
sleeve to ’A’ post.
10. If necessary adjust door.
See Adjustment.
GLASS - FRONT DOOR
Service repair no - 76.31.01
Remove
1. Remove front door outer waist seal.
See this
section.
2. Remove front door plastic sheet.
See this
section.
3. Turn ignition ON.
4. Lower glass approximately 120mm (5 in.)
Remove rear regulator arm retaining clip.
5. Lower glass to align forward clip with the
regulator plate lower retaining rivet. Turn ignition
OFF.
76
CHASSIS AND BODY NEW RANGE ROVER
28
REPAIR
6. Remove front lower fixing clip.
7. Remove nut securing bracket to vertical slide.
8. Release bracket from slide.
CAUTION: Chock glass with wooden
block, or retain with tape, to prevent glass
dropping when regulator arms are
released.
9. Using a suitable lever, release 2 regulator arms
from glass lower fixings.
10. Support weight of glass. Remove wooden chock
or tape.
11. Rotate glass anti-clockwise to release from
runners.
12. Remove front door glass.
Refit
13. Refit front door glass.
14. Rotate glass anti-clockwise, fit to runners.
15. Secure glass fixings to regulator arms.
16. Position glass bracket to vertical runner, fit
retaining nut.
17. Fit clip securing regulator arm to glass runner.
18. Turn ignition ON.
19. Raise door glass approximately 120mm (5 in.)
Fit rear glass retaining clip.
20. Raise door glass.
21. Turn ignition OFF.
22. Fit front door plastic sheet.
See this section.
23. Fit front door outer waist seal.
See this section.
CHASSIS AND BODY
29
REPAIR
GLASS REGULATOR - FRONT DOOR
Service repair no - 76.31.45
Remove
1. Remove front door glass.
See this section.
2. Disconnect window lift motor harness connector.
3. Remove rivet securing regulator runner to door
panel.
4. Remove 3 rivets.
5. Remove regulator assembly.
Refit
6. Reverse removal procedure.
LATCH - FRONT DOOR
Service repair no - 76.37.12
Remove
1. Remove front door trim casing.
See this
section.
2. Release rear of plastic sheet.
3. Release retaining clip, private lock to latch
operating rod, at latch end.
4. Release control rod from latch.
5. Release retaining clip, outside handle to latch
operating rod, at latch end.
6. Release control rod from latch.
7. Disconnect 2 latch motor multiplugs.
8. Remove door sill button from operating rod.
9. Release remote handle to latch operating cable
from clip.
10. Remove 3 screws securing latch.
11. Release latch from door.
12. Remove sill button operating rod from latch.
76
CHASSIS AND BODY NEW RANGE ROVER
30
REPAIR
13. Release outer operating cable from latch
abutment.
14. Release inner cable from latch.
15. Remove latch from door.
Refit
16. Fit latch.
17. Fit inner operating cable to latch.
18. Fit outer operating cable to latch abutment.
19. Fit sill button operating rod to latch.
20. Align latch to door, tighten 3 screws.
21. Secure remote handle cable to door panel clip.
22. Fit sill button to operating rod.
23. Reconnect 2 latch motor multiplugs.
24. Fit outside handle operating rod to latch.
25. Fit retaining clip.
26. Fit private lock operating rod to latch.
27. Fit retaining clip.
28. Secure plastic sheet.
29. Fit front door trim casing.
See this section.
CHASSIS AND BODY
31
REPAIR
REMOTE CONTROL - FRONT DOOR
Service repair no - 76.37.31
Remove
1. Remove front door trim casing.
See this
section.
2. Release top rear corner of plastic sheet.
3. Pull remote handle out. Release inner cable from
remote handle.
4. Release remote handle.
5. Remove 2 screws securing remote handle.
6. Remove outer cable from housing.
7. Remove remote by sliding rearwards.
Refit
8. Reverse removal procedure.
OUTER WAIST SEAL - FRONT DOOR
Service repair no - 76.31.53
Remove
1. Remove screw securing rear edge of outer waist
seal.
2. Remove outer waist seal.
Refit
3. Reverse removal procedure.
76
CHASSIS AND BODY NEW RANGE ROVER
32
REPAIR
OUTSIDE HANDLE - FRONT DOOR
Service repair no - 76.58.07
Remove
1. Remove front door trim casing.
See this
section.
2. Release rear half of plastic sheet.
3. Remove retaining clip, private lock to latch
operating rod, at latch end.
4. Remove control rod from latch and private lock.
5. Remove retaining clip, outside handle to latch
operating rod, at latch end.
6. Remove control rod from latch and outside
handle.
7. Remove bolt securing rear of outside handle.
8. Slide outside handle forwards. Pull handle out,
release rear of handle from door.
CHASSIS AND BODY
33
REPAIR
9. Remove handle from front fixing by pivotting rear
end of handle out.
10. Remove gasket from handle.
11. Remove rubber locking plate from door.
12. Remove plastic locking plate from door.
13. Remove screw securing mounting plate to door,
remove plate.
Refit
14. Clean handle and door mating faces.
15. Reverse removal procedure.
PLASTIC SHEET - FRONT DOOR
Service repair no - 76.34.26
Remove
1. Remove front door trim casing.
See this
section.
2. Remove 2 screws securing door outstation ECU.
3. Remove 2 screws securing speaker amplifier.
4. Remove 4 screws securing front door speaker.
5. Release speaker, disconnect multiplug.
6. Remove plastic sheet.
Refit
7. Reverse removal procedure.
76
CHASSIS AND BODY NEW RANGE ROVER
34
REPAIR
PRIVATE LOCK - FRONT DOOR
Service repair no - 76.37.39
Remove
1. Remove outside handle.
See this section.
2. Fit door lock key.
3. Remove screw securing lock.
4. Remove cam and washer from lock.
5. Remove cam lock and stop from lock.
6. Remove cam return spring. Remove lock from
outside handle.
Refit
7. Apply grease to lock barrel.
8. Fit lock to outside handle.
9. Fit cam return spring, cam stop, cam lock,
washer and cam.
10. Fit screw securing lock to outside handle.
11. Remove door lock key.
12. Refit front door outside handle.
See this
section.
TRIM CASING - FRONT DOOR
Service repair no - 76.34.01
Remove
1. Release cheater panel.
2. Disconnect 2 tweeter speaker connectors,
remove cheater panel.
3. Remove screw securing remote handle
escutcheon, remove escutcheon.
4. Remove 3 screws securing trim casing.
5. Release 12 clips retaining trim casing.
CHASSIS AND BODY
35
REPAIR
6. Disconnect speaker connector.
7. Remove door trim casing.
Disassemble
8. Remove 12 trim casing retaining clips.
9. Remove 4 screws, remove speaker.
10. Remove 4 screws, remove speaker grille.
11. Remove 7 screws, remove trim casing pocket.
12. Remove 3 screws, remove arm rest.
13. Remove retaining clamp and sill button
escutcheon.
76
CHASSIS AND BODY NEW RANGE ROVER
36
REPAIR
14. Remove door trim casing waist seal.
Assemble
15. Fit door trim casing waist seal.
16. Fit sill button escutcheon, position retaining
clamp, tighten screw.
17. Fit arm rest to trim casing, tighten 3 screws.
18. Fit trim casing pocket, tighten 7 screws.
19. Fit speaker grille to trim casing, tighten 4 screws.
20. Fit speaker to trim, tighten 4 screws.
21. Fit 12 retaining clips.
Refit
22. Connect trim casing speaker connector.
23. Fit trim casing, locating 12 retaining clips.
24. Fit 3 screws securing trim casing.
25. Fit remote handle escutcheon, tighten screw.
26. Position cheater panel, connect 2 tweeter
speaker connectors.
27. Secure cheater panel.
INSERT CAPPING - FRONT DOOR
Service repair no - 76.34.32
Remove
1. Fit protection to door trim casing.
2. Position a blunt flat blade between trim casing
and insert upper edge.
3. Gently raise blade to remove insert.
4. Remove retaining clips from insert.
Refit
5. Fit insert to door casing. Secure with clips.
6. Remove protection from door casing.
CHASSIS AND BODY
37
REPAIR
REAR DOOR ASSEMBLY
Service repair no - 76.28.02/99
Remove
1. Release door harness protective sleeve from
’B/C’ post.
2. Disconnect door harness multiplugs.
3. Remove check strap retaining pin.
CAUTION: Apply protective tape to ’B/C’
post before drifting out pin.
4. Remove hinge pin retaining clips.
5. With assistance, remove door assembly.
Refit
6. With assistance fit door to hinges.
7. Fit hinge retaining clips.
8. Align check strap and fit retaining pin.
9. Remove protective tape.
10. Connect harness multiplugs, secure protective
sleeve to ’B/C’ post.
11. If necessary adjust door.
See Adjustment.
GLASS - REAR DOOR
Service repair no - 76.31.02
Remove
1. Remove outer waist seal.
See this section.
2. Remove door trim casing.
See this section.
3. Remove speaker and plastic sheet.
See this
section.
4. Remove window motor and control panel
assembly.
See ELECTRICAL, Repair.
5. Remove glass rear channel.
See this section.
6. Remove wedges or tape from glass.
7. Release glass from channel. Raise to remove
glass from door.
Refit
8. Fit glass to door and align to frame.
9. Wedge or use tape to hold glass in door.
10. Fit glass rear channel.
See this section.
11. Fit window motor and control panel.
See
ELECTRICAL, Repair.
12. Fit speaker and plastic sheet.
See this section.
13. Fit trim casing.
See this section.
14. Fit outer waist seal.
See this section.
76
CHASSIS AND BODY NEW RANGE ROVER
38
REPAIR
PLASTIC SHEET - REAR DOOR
Service repair no - 76.34.28
Remove
1. Remove rear door trim casing.
See this
section.
2. Remove speaker.
See ELECTRICAL, Repair.
3. Remove 2 screws securing amplifier to door.
4. Remove plastic sheet.
Refit
5. Reverse removal procedure.
OUTSIDE HANDLE - REAR DOOR
Service repair no - 76.58.02
Remove
1. Remove rear door trim casing.
See this
section.
2. Remove bolt securing handle.
3. Remove outside handle.
NOTE: Operate and pull handle outward,
pivotting at forward mounting point.
4. Remove gasket.
5. Remove locking plates.
6. Remove screw securing mounting plate, remove
plate.
CHASSIS AND BODY
39
REPAIR
Refit
7. Clean handle face on door.
8. Fit handle mounting plate, tighten screw.
9. Fit locking plates.
10. Fit gasket to handle, position handle, secure with
screw.
11. Refit door trim casing.
See this section.
LATCH - REAR DOOR
Service repair no - 76.37.13/70
Remove
1. Remove window lift motor/control unit assembly.
See ELECTRICAL, Repair.
2. Release door lock remote control cable from clip
on window lift panel.
3. Remove 2 studs securing latch to window lift
panel.
4. Disconnect outer cable from abutment bracket.
5. Release remote cable from latch.
6. Release sill button link rod from latch. Remove
latch.
Refit
7. Lubricate new latch.
8. Fit latch to sill button link rod.
9. Fit remote control cable to latch.
10. Fit latch to window lift panel, secure with 2
retaining studs.
11. Refit window lift motor/control unit assembly.
See ELECTRICAL, Repair.
76
CHASSIS AND BODY NEW RANGE ROVER
40
REPAIR
FIXED QUARTER LIGHT - REAR DOOR
Service repair no - 76.31.31
Remove
1. Remove outer waist seal.
See this section.
2. Remove door trim casing.
See this section.
3. From inside release seal from frame. Remove
seal and glass assembly outwards.
4. Remove seal from glass.
Refit
5. Clean glass, seal and frame.
6. Fit seal to glass. Fit assembly to door frame. If
necessary use a draw string to locate rubber.
NOTE: The opening light seal fits over the
fixed glass seal.
7. Fit door trim casing.
See this section.
8. Fit outer waist seal.
See this section.
REMOTE CONTROL - REAR DOOR
Service repair no - 76.37.32
Remove
1. Remove rear door trim casing.
See this
section.
2. Release plastic sheet to clear remote.
3. Remove foam pad from under window lift switch
multiplug.
4. Disconnect switch multiplug.
5. Release inner cable from remote lever.
6. Remove 2 screws securing remote to window lift
control panel.
7. Release remote outer cable from remote
housing.
8. Remove remote control.
Refit
9. Reverse removal procedure.
CHASSIS AND BODY
41
REPAIR
GLASS CHANNEL - REAR DOOR
Service repair no - 76.31.17
Remove
1. Remove window lift motor/control panel
assembly.
See ELECTRICAL, Repair.
2. Remove 2 bolts securing channel to door and
remove channel.
Refit
3. Fit channel to door, secure with 2 bolts.
4. Refit window lift motor/control panel assembly.
See ELECTRICAL, Repair.
SEAL - REAR DOOR
Service repair no - 76.40.02
Remove
1. Open rear door.
2. Remove rear door carpet retainer.
3. Remove rear door aperture seal.
Refit
4. Fit rear door aperture seal.
5. Refit rear door carpet retainer.
6. Close rear door.
TRIM CASING - REAR DOOR
Service repair no - 76.34.04
Remove
1. Remove remote handle escutcheon.
76
CHASSIS AND BODY NEW RANGE ROVER
42
REPAIR
2. Remove 2 screws securing trim casing.
3. Release 11 door trim casing retaining studs.
4. Disconnect rear door speaker connector.
Remove door trim casing.
Disassemble
5. Remove 11 trim casing retaining studs.
6. Remove 4 screws, remove upper speaker grille.
7. Remove 4 screws, remove lower speaker grille.
8. Remove 3 screws, remove arm rest.
9. Remove screw, remove retaining clamp and sill
button escutcheon.
CHASSIS AND BODY
43
REPAIR
10. Remove trim from door casing.
Assemble
11. Fit trim to door casing.
12. Fit sill button escutcheon and position retaining
clamp.
13. Tighten screw securing retaining clamp.
14. Fit arm rest to trim casing, secure with 3 screws.
15. Fit upper speaker grille to trim casing, secure
with 4 screws.
16. Fit lower speaker grille to trim casing, secure
with 4 screws.
17. Fit 11 trim casing retaining studs.
Refit
18. Fit and align door trim casing.
19. Secure 11 trim casing retaining studs.
20. Tighten 2 screws securing trim casing.
21. Fit remote handle escutcheon, tighten securing
screw.
OUTER WAIST SEAL - REAR DOOR
Service repair no - 76.31.54
Remove
1. Remove screw securing seal finisher to forward
edge of door.
2. Release seal finisher from clip at rear edge of
door.
3. Remove seal and finisher assembly.
4. Remove screw and securing clip.
Refit
5. Fit clip to door, secure with screw.
6. Fit seal and finisher assembly to door. Align at
forward edge, secure with screw.
76
CHASSIS AND BODY NEW RANGE ROVER
44
REPAIR
RUBBING STRIPS & DOOR FINISHERS
Remove
CAUTION: When removing exterior trim,
NEVER lever directly against body panels.
Use an approved trim fork. Protect body
panel with suitable material, such as fabric
covered hardboard.
Rubbing Strip - Front Fender
1. Remove relevant wheel arch liner.
See this
section.
2. Remove nut securing forward edge of rubbing
strip.
3. Remove rubbing strip from single clip.
Rubbing Strip - Rear Quarter Panel
4. Release 5 clips securing rubbing strip. Remove
strip.
NOTE: Rearmost clip is unique.
Rubbing Strips - Front & Rear Doors
5. Remove nut securing rear of rubbing strip.
6. Front Door Rubbing Strip: Release 5 clips
securing rubbing strip.
7. Rear Door Rubbing Strip: Release 3 clips
securing rubbing strip.
8. Remove rubbing strips.
Lower Door Finishers
9. Remove screw securing rear of fininsher.
10. Front Door Finisher: Release 5 clips securing
rubbing strip.
11. Rear Door Finisher: Release 3 clips securing
rubbing strip.
12. Remove finishers.
Refit
13. Reverse removal procedure.
GLOVE BOX AND LID
Service repair no - 76.52.03 - Glove Box
Service repair no - 76.52.02 - Glove Box Lid
Service repair no - 76.52.13 - Glove Box Lid - Align
Remove
1. Remove centre screw from 2 scrivet fasteners.
Release closing panel for access to glove box
hinge fixings. Collect outer parts of fasteners
from closing panel.
2. Remove 2 bolts securing glove box hinges to
fascia frame.
3. Open glove box lid, remove 5 screws securing
glove box. Release glove box from fascia.
4. Disconnect glove box lamp multiplug.
CHASSIS AND BODY
45
REPAIR
5. Disconnect cable latch, remove glove box
assembly.
Glove Box Lid
6. Remove split pin, disengage gas strut from lid.
7. Remove 2 bolts and square nuts, remove lid
from glove box.
Refit Glove Box Lid
8. Position lid to glove box and secure with bolts
and square nuts.
9. Engage gas strut, secure with split pin.
Refit Glove Box Assembly
10. Position glove box assembly, connect lamp
multiplug. Secure cable latch.
11. Open glove box lid, align assembly to fascia.
Secure with screws.
12. Fit bolts securing hinges to fascia frame, do no
tighten.
13. Check alignment and latching of glove box lid,
adjusting hinges as necessary using central
adjusting screws.
14. Tighten screws, hinges to fascia.
15. Close glove box lid.
16. Position closing panel. Secure with scrivet
fasteners.
76
CHASSIS AND BODY NEW RANGE ROVER
46
REPAIR
GLOVE BOX RELEASE CABLE
Service repair no - 76.52.14
NOTE: Release cables are supplied preset
and do not normally require adjustment.
Remove
1. Open glove box. Remove 5 screws securing
glove box liner to fascia.
2. Lower glove box liner. Release 2 clips to
disengage cable latch from location.
3. Remove finisher from lock.
4. Remove 2 screws securing lock and withdraw
cable assembly from fascia.
5. Pry cover from lock button.
6. Insert key into lock, turn key through 45 degrees,
remove barrel.
Refit
7. Insert barrel, turn to engage in button.
8. Remove key, fit cover to lock button.
9. Route release cable assembly into fascia.
Engage cable latch to glove box.
10. Align glove box liner to fascia, tighten screws.
11. Close glove box lid.
12. Position glove box lock to fascia, check
operation of latch.
13. If adjustment is necessary, release lock from
fascia, loosen cable lock nut, adjust outer cable
length. Tighten cable lock nut.
14. Reposition lock to fascia. Recheck operation of
latch before securing lock with screws.
15. Fit finisher to lock.
CHASSIS AND BODY
47
REPAIR
GRAB HANDLE
Service repair no - 76.58.30
Remove
1. Pull down grab handle.
2. Remove 2 grab handle retaining screw access
covers.
3. Remove 2 screws, remove grab handle.
Refit
4. Position grab handle, fit 2 retaining screws.
5. Fit 2 retaining screw access covers.
6. Release grab handle.
FRONT GRILLE
Service repair no - 76.55.03
Remove
1. Remove 6 screws securing grille.
2. Remove front grille.
Refit
3. Reverse removal procedure.
76
CHASSIS AND BODY NEW RANGE ROVER
48
REPAIR
EXTERIOR MIRROR
Service repair no - 76.10.52
Remove
1. Release cheater panel, disconnect 2 tweeter
speaker connectors. Remove cheater panel.
2. Disconnect mirror multiplug.
3. Remove 3 screws, remove mirror.
Refit
4. Fit mirror, tighten 3 retaining screws.
5. Connect mirror multiplug.
6. Position cheater panel, connect 2 tweeter
speaker connectors, secure panel to door.
INTERIOR MIRROR
Service repair no - 76.10.51
Remove
1. Remove cover.
2. If fitted, diconnect multiplug.
3. Remove mirror from windscreen location by
pulling sharply downwards.
Refit
4. Reverse removal procedure.
CHASSIS AND BODY
49
REPAIR
PARCEL TRAY SUPPORT
Service repair no - 76.67.11
Remove
1. Release 2 squab catches and fold rear seats
forward.
2. Remove parcel tray.
3. Remove 3 studs securing parcel tray support.
Remove support.
Refit
4. Reverse removal procedure.
PARCEL TRAY SUPPORT TRIM
Service repair no - 76.67.12 - Right Hand
Service repair no - 76.67.21 - Left Hand
Remove
1. Remove parcel tray support.
See this section.
2. Remove ’D’ post lower trim.
3. Release tailgate aperture seal from support trim
flange.
4. Remove 3 trim studs.
LH Trim Only
5. Remove CD autochanger.
See ELECTRICAL,
Repair.
6. Remove 2 nuts and 2 bolts securing sub-woofer
assembly.
76
CHASSIS AND BODY NEW RANGE ROVER
50
REPAIR
7. Disconnect multiplug from sub-woofer.
Both Trim Panels
8. Release 2 sprag clips securing support trim to
body.
9. Remove support trim panel.
10. LH Trim Only: Separate sub-woofer from trim
panel.
Refit
11. Reverse removal procedure.
A,B,D and E POST TRIMS
Remove
1. Remove aperture seal from appropriate area.
2. Remove retaining screws (’A’ post lower trims)
3. Remove seat belt top mounting (’B’ and ’D’ post
upper trims)
4. Release retaining clips, remove finisher.
Refit
5. Position finisher, secure with retaining clips and
screws.
6. Fit seat belt top mounting. Tighten to
25 Nm.
(18lbf. ft)
7. Secure aperture seal.
NOTE: Illustration 76M 7128 shows the
fixing method for the A, B, D and E post
trim finishers.
1. A post upper
2. A post lower left hand
3. A post lower right hand
4. B post upper
5. B post lower
6. D post upper
7. D post lower
8. E post
CHASSIS AND BODY
51
REPAIR
76
CHASSIS AND BODY NEW RANGE ROVER
52
REPAIR
’E’ POST - EXTERIOR TRIM
Service repair no - 76.43.
Remove
1. Open upper tailgate.
2. Remove 3 screws securing trim to ’E’ post.
3. Remove trim.
Refit
4. Position trim to ’E’ post, engage slot beneath
special washer on tailgate strut ball joint and
engage channel to rear edge of quarter glass.
5. Secure trim with screws.
6. Close tailgate.
SEAT BELT - FRONT
Service repair no - 76.73.13
Remove
1. Remove lower ’B’ post finisher.
2. Remove cover and nut securing seat belt to
upper anchorage point.
3. Release seat belt guide from ’B’ post.
4. Move seat fully forwards.
5. Remove bolt cover. Release seat belt from lower
anchorage point on seat.
CHASSIS AND BODY
53
REPAIR
6. Remove bolt securing belt reel to ’B’ post,
remove belt reel.
7. Move seat fully rearwards.
8. Remove cover from seat belt stalk fixing.
Remove bolt. Collect stalk.
Refit
9. Position seat belt stalk. Secure with retaining
bolt. Tighten to
35 Nm. (26 lbf.ft).
Fit bolt
cover.
10. Fit seat belt reel to ’B’ post. Secure with retaining
bolt. Tighten to
35 Nm. (26 lbf.ft)
11. Move seat fully forwards.
12. Secure seat belt to lower anchorage point. Fit
bolt cover.
WARNING: Ensure that belt is correctly
located before fitting bolt cover.
13. Align belt to upper anchorage point. Secure with
nut. Tighten to
25 Nm. (18 lbf.ft).
Fit cover.
14. Secure seat belt guide to ’B’ post.
15. Refit lower ’B’ post finisher.
76
CHASSIS AND BODY NEW RANGE ROVER
54
REPAIR
FRONT SEAT BELT ADJUSTABLE MOUNTING
Service repair no - 76.73.26
Remove
1. Remove ’B’ post trim upper.
2. Remove 2 screws securing adjustable mounting.
Remove mounting.
Refit
3. Position adjustable mounting. Secure with
screws. Tighten to
25 Nm. (18 lbf.ft)
4. Fit ’B’ post trim upper.
SEAT BELT ADJUSTABLE MOUNTING - ’D’ POST
Service repair no - 76.73.36
Remove
1. Remove ’D’ post trim - upper.
2. Remove 2 screws securing adjustable mounting.
Remove mounting.
Refit
3. Position adjustable mounting. Secure with
screws. Tighten to
25 Nm. (18 lbf.ft)
4. Refit ’D’ post trim - upper.
CHASSIS AND BODY
55
REPAIR
REAR SEAT BELT - CENTRE
Service repair no - 76.73.20
Remove
1. Remove right hand rear seat.
See SEATS,
Repair.
2. Remove 3 screws securing squab hinge cover.
Remove cover.
3. Remove 2 bolts securing squab to cushion
assembly.
4. Remove squab from cushion assembly.
5. Remove bolt and wave washer securing stalk to
squab hinge. Remove stalk. Collect plain
washer.
6. Release beaded edge of cushion cover from
seat pan flange. Remove cushion cover/foam
assembly.
CAUTION: Take care when releasing
cover/foam from belt anchorage finisher.
76
CHASSIS AND BODY NEW RANGE ROVER
56
REPAIR
7. Remove 3 screws securing anchorage cover to
seat pan. Remove cover in 2 pieces.
8. Remove bolt securing seat belt to seat pan.
Remove belt, collect spacer.
Refit
9. Fit seat belt to seat pan. Secure with bolt and
spacer. Tighten to
35 Nm. (26 lbf.ft)
10. Fit seat belt anchorage cover. Secure with
screws.
11. Fit cushion assembly to seat pan. Secure
beaded edge of cover to seat pan flange.
12. Fit stalk to squab hinge. Secure with bolt.
Tighten to
35 Nm. (26 lbf.ft)
13. Position seat squab to cushion assembly.
Secure with bolts. Tighten to
45 Nm. (33 lbf.ft)
14. Refit squab hinge cover. Secure with screws.
15. Refit rear seat assembly.
See SEATS, Repair.
CHASSIS AND BODY
57
REPAIR
REAR SEAT BELT - LEFT HAND
Service repair no - 76.73.23
Remove
1. Remove parcel shelf support trim.
See this
section.
2. Remove ’D’ post lower trim.
See this section.
3. Remove cover and nut securing seat belt to
upper anchorage point.
4. Remove bolt securing seat belt reel.
5. Remove seat belt reel.
6. Remove left hand rear seat.
See SEATS,
Repair.
7. Remove 3 screws securing squab hinge cover.
Remove cover.
8. Remove 2 bolts securing squab to cushion
assembly.
9. Remove squab from cushion assembly.
10. Remove bolt and wave washer securing stalk to
squab hinge.
11. Remove stalk. Collect plain washer.
Refit
12. Fit stalk to squab hinge. Secure with bolt.
Tighten to
35 Nm. (26 lbf.ft)
13. Position seat squab to cushion assembly.
Secure with bolts. Tighten to
45 Nm. (33 lbf.ft)
14. Refit squab hinge cover. Secure with screws.
15. Refit rear seat assembly.
See SEATS, Repair.
16. Position belt to upper anchorage point. Secure
with nut. Tighten to
25 Nm. (18 lbf.ft).
Fit
cover.
17. Position seat belt reel. Secure with bolt. Tighten
to
35 Nm. (26 lbf.ft)
18. Fit ’D’ post lower trim.
See this section.
19. Fit parcel shelf support trim.
See this section.
76
CHASSIS AND BODY NEW RANGE ROVER
58
REPAIR
REAR SEAT BELT - RIGHT HAND
Service repair no - 76.73.24
Remove
1. Remove parcel shelf support trim.
See this
section.
2. Remove ’D’ post lower trim.
3. Remove cover and nut securing seat belt to
upper anchorage point.
4. Remove bolt securing seat belt reel.
5. Remove seat belt reel.
6. Remove right hand rear seat.
See SEATS,
Repair.
7. Remove 3 screws securing squab hinge cover.
Remove cover.
8. Remove 2 bolts securing squab to cushion
assembly. Remove squab.
9. Release beaded edge of cushion cover from
seat pan flange. Remove cushion cover/foam
assembly.
CHASSIS AND BODY
59
REPAIR
CAUTION: Take care when releasing
cover/foam from belt anchorage finisher.
10. Remove 3 screws securing anchorage cover to
seat pan. Remove cover in 2 pieces.
11. Remove bolt securing stalk to seat pan. Remove
stalk. Collect 2 spacers and wave washer.
76
CHASSIS AND BODY NEW RANGE ROVER
60
REPAIR
Refit
12. Fit stalk to seat pan. Secure with bolt, spacers
and wave washer. Tighten to
35 Nm. (26 lbf.ft)
13. Fit seat belt anchorage cover. Secure with
screws.
14. Fit cushion assembly to seat pan. Secure
beaded edge of cover to seat pan flange.
15. Fit stalk to squab hinge. Secure with bolt.
Tighten to
35 Nm. (26 lbf.ft)
16. Position seat squab to cushion assembly.
Secure with bolts. Tighten to
45 Nm. (33 lbf.ft)
17. Refit squab hinge cover. Secure with screws.
18. Refit rear seat assembly.
See SEATS, Repair.
19. Position belt to upper anchorage point. Secure
with nut. Tighten to
35 Nm. (26 lbf.ft).
Fit
cover.
20. Position seat belt reel. Secure with bolt. Tighten
to
35 Nm. (26 lbf.ft)
21. Fit ’D’ post lower trim.
22. Fit parcel shelf support trim.
See this section.
CHASSIS AND BODY
61
REPAIR
SLIDING ROOF - ELECTRIC
Service repair no - 76.82.44
Remove
1. Remove headlining.
See this section.
2. Disconnect motor multiplug.
3. Disconnect sliding roof drain tubes.
4. Remove 8 bolts securing sliding roof.
5. With assistance, remove 2 remaining bolts.
Remove sliding roof.
6. Remove seal from sliding roof.
Refit
7. Ensure mating faces are clean.
8. Fit new seal to sliding roof.
9. With assistance, position sliding roof. Fit 2 bolts.
10. Fit remaining bolts.
11. Connect drain tubes. Secure with clips.
12. Connect motor multiplug.
13. Refit headlining.
See this section.
76
CHASSIS AND BODY NEW RANGE ROVER
62
REPAIR
HEADLINING - SLIDING ROOF
Service repair no - 76.64.15
Remove
1. Remove upper trims from ’A’,’B’,’D’ & ’E’ posts.
See this section.
2. Remove both sun visors.
See this section.
3. Remove grab handles.
See this section.
4. Remove parcel tray support trim.
See this
section.
5. Remove interior lamps.
See ELECTRICAL,
Repair.
6. Remove front courtesy lamp.
See
ELECTRICAL, Repair.
7. Remove ultrasonic sensor.
See ELECTRICAL,
Repair.
8. Fold down rear seat squabs. Recline front seat
squabs.
9. Release aperture sealing rubbers at tops of
doors and tailgate.
10. Release sun visor clip retaining screw cover
plugs.
11. Remove sun visor retaining clip screws. Remove
clips.
12. Remove sun roof aperture finisher.
13. Remove 2 headlining grab handle blanks.
14. Remove 2 studs securing rear of headlining.
15. With assistance remove headlining.
Refit
16. Reverse removal procedure.
CHASSIS AND BODY
63
REPAIR
SUNROOF DRAIN TUBE - FRONT
Service repair no - 76.82.21
Remove
1. Remove headlining.
See this section.
2. Remove wheelarch liner.
See this section.
3. Release drain tube from sunroof.
4. Release drain tube grommet from body behind
wheel arch liner.
5. Tie draw string to one end of drain tube and pull
tube from ’A’ post.
Refit
6. Tie draw string to new drain tube and pull
through ’A’ post.
7. Fit grommet to drain tube, secure to body.
8. Secure drain tube to sunroof.
9. Fit headlining.
See this section.
10. Refit wheel arch liner.
See this section.
76
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64
REPAIR
SUNROOF DRAIN TUBE - REAR
Service repair no - 76.82.22
Remove
1. Remove headlining.
See this section.
NOTE: Ensure that parcel shelf support
panel is removed from side of drain tube
to be removed.
2. Release clip from drain tube.
3. Disconnect drain tube from sunroof.
4. Remove drain tube from wheel arch grommet.
Refit
5. Fit drain tube to sunroof, secure with clip.
6. Fit drain tube through wheel arch grommet.
7. Refit headlining.
See this section.
CHASSIS AND BODY
65
REPAIR
SUN VISOR
Service repair no - 76.10.47
Remove
1. Release visor from clip.
2. Remove 3 visor retaining screws.
3. Disconnect visor lamp multiplug.
4. Remove visor.
5. Remove clip if required. Carefully lever plastic
tag down.
6. Remove screw, remove clip.
Refit
7. Reverse removal procedure.
SILL FINISHER
Service repair no - 76.43.84
Remove
1. Remove 3 screws securing front tread plate.
2. Remove 2 screws securing rear tread plate.
3. Remove trim stud securing rear of sill finisher.
4. Release 8 clips securing finisher to sill.
5. Remove sill finisher.
Refit
6. Renew clips as necessary.
7. Reverse removal procedure.
76
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66
REPAIR
TAILGATE - UPPER
Service repair no - 76.28.29
Remove
1. Remove both ’E’ post finishers.
2. Remove 2 trim fixing studs. Release headlining
from ’E’ posts.
3. Release 4 turn buckles securing access panel to
LH side load space trim. Remove panel.
4. Locate rear screen washer non-return valve.
Disconnect tailgate feed tube from valve.
5. Attach draw string to tube to aid re-assembly.
6. Release tailgate harness protective sleeve from
roof panel.
7. Disconnect 3 tailgate harness multiplugs from
body harness. Pull plugs out through hole in roof
panel.
8. Pull screen washer tube out through hole in roof
panel. Disconnect draw string.
9. Mark outline of hinge on tailgate to aid
re-assembly.
10. Apply protective tape to roof panel before
releasing tailgate.
11. With assistance, disconnect gas struts from
tailgate.
12. With assistance, remove 4 bolts securing hinges
to tailgate. Remove tailgate.
CHASSIS AND BODY
67
REPAIR
Refit
13. With assistance, position tailgate to hinges. Align
marks. Secure with bolts. Tighten to
25 Nm. (18
lbf.ft)
14. With assistance, connect gas struts to tailgate.
15. Remove protective tape from roof panel.
16. Attach draw string to washer tube. Pull tube
along roof into position at ’E’ post. Remove draw
string.
17. Connect tube to non-return valve.
18. Feed 3 tailgate harness multiplugs through roof
panel. Connect to body harness.
19. Secure tailgate harness protective sleeve to roof
panel.
20. Reposition headlining at ’E’ posts. Secure with
studs.
21. Fit load space access panel. Secure with turn
buckles.
22. Fit both ’E’ post finishers.
Adjust
23. Check alignment of lower tailgate.
See this
section.
24. Align tailgate to aperture by adjusting position of
hinges on tailgate or body.
25. Align tailgate to adjacent body panels by
adjusting position of hinges on body.
NOTE: To prevent wind noise, ensure top
edge of tailgate does not stand proud of
roof panel.
TAILGATE - LOWER
Service repair no - 76.28.30
Remove
1. Remove parcel tray support trim from RH side of
luggage area.
See this section.
2. Disconnect tailgate harness multiplug from body
harness. Release grommet from lower of ’E’
post. Pull harness from body.
3. Fit protection under tailgate.
4. Mark outline of hinges to body to aid
reassembly.
5. Remove bolt securing each check strap to body.
Collect spacer and fibre sealing washer.
76
CHASSIS AND BODY NEW RANGE ROVER
68
REPAIR
6. With assistance, remove bolts securing tailgate
hinges to body. Remove tailgate complete with
hinges.
Refit
7. With assistance, position tailgate to body.
Secure with bolts. Tighten to
25 Nm. (18 lbf.ft)
8. Position support stays with spacer and sealing
washer next to body. Tighten to
22 Nm. (16
lbf.ft)
9. Remove protection.
10. Feed tailgate harness into ’E’ post. Connect
multiplug to body harness.
11. Fit harness grommet to ’E’ post.
12. Fit parcel tray support trim.
See this section.
Adjust
13. Align tailgate to aperture by adjusting position of
hinges on tailgate or body.
14. Align tailgate to adjacent body panels by
adjusting position of hinge to tailgate.
15. When tailgate alignment is correct, adjust height
and inboard/outboard position of each striker.
Tighten striker bolts. Check for correct latching.
16. Slacken bolts, re-adjust striker positions as
necessary. Tighten to
8 Nm. (6 lbf.ft)
TAILGATE STRIKER
Service repair no - 76.37.26
Remove
1. Remove 2 bolts securing striker. Remove striker.
Refit
2. Position striker. Secure with bolts
3. Close tailgate. Check alignment.
4. If necessary, open tailgate, slacken bolts, realign
striker. Re-tighten bolts.
CHASSIS AND BODY
69
REPAIR
TAILGATE LATCH
Service repair no - 76.37.17
Remove
1. Release studs securing tailgate board. Remove
board.
2. Release clips securing operating rods to tailgate
centre latch. Release rods.
3. Disconnect latch multiplug.
4. Remove 2 bolts securing latch to tailgate.
Remove latch.
Refit
5. Reverse removal procedure.
TAILGATE LATCH - OUTER
Service repair no - 76.37.73
Remove
1. Release studs securing tailgate board. Remove
board.
2. Release clip securing outer latch rod. Disconnect
rod from centre latch.
76
CHASSIS AND BODY NEW RANGE ROVER
70
REPAIR
3. Remove 2 bolts securing outer latch to tailgate.
Remove latch and rod.
4. Rotate release rod 90Ëš to remove from outer
latch.
Refit
5. Reverse removal procedure.
UPPER TAILGATE - INTERIOR TRIM
Service repair no - 76.34.13
Remove
Lower trim assembly
1. Release load space lamp from trim panel,
disconnect 2 Lucar terminals and remove lamp.
2. Remove 6 screws securing trim panel to side
trims and tailgate.
3. Release 4 studs securing trim panel to tailgate.
4. Disconnect high level stop lamp multiplug, if
fitted.
5. Remove lower trim assembly.
Upper trim
6. Remove 6 screws securing trim panel to tailgate.
CHASSIS AND BODY
71
REPAIR
7. Remove trim panel and collect 2 foam pads.
Side trims
8. Release 3 studs securing each side trim.
9. Remove 2 side trims.
Refit
10. Reverse removal procedure.
TAILGATE STRUT
Service repair no - 76.40.33
Remove
1. Secure tailgate in open position using suitable
support.
2. Release clips securing strut to ball joints.
Remove strut.
Refit
3. Reverse removal procedure.
76
CHASSIS AND BODY NEW RANGE ROVER
72
REPAIR
WHEEL ARCH LINER - FRONT
Service repair no - 76.10.48
Remove
1. Raise the vehicle.
WARNING: Support on safety stands.
2. Remove relevant road wheel.
3. Remove 3 screws securing mud flap. Remove
mud flap.
4. Remove 8 studs securing wheel arch liner.
Refit
5. Position liner and secure with trim studs.
6. Fit mud flap and secure with screws.
7. Refit road wheel. Secure with nuts. Tighten to
108 Nm. (80 lbf.ft)
8. Remove safety stands. Lower vehicle.
WHEEL ARCH LINER - REAR
Service repair no - 76.10.49
Remove
1. Raise the vehicle.
WARNING: Support on safety stands.
2. Remove relevant road wheel.
3. Remove screws from wheel arch liner fixings.
Remove fixings.
4. Remove liner.
Refit
5. Position liner. Fit liner fixings. Secure with
screws.
6. Refit road wheel. Secure with nuts. Tighten to
108 Nm. (80 lbf.ft)
7. Remove safety stands. Lower vehicle.
CHASSIS AND BODY
73
REPAIR
WINDSCREEN
Service repair no - 76.81.01
NOTE: The following equipment is
required:
masking tape;
sharp knife;
reciprocating blade, powered cutting knife*, or
cutting wire and handles;
suction lifters;
windscreen repair kit;
sealer applicator gun.
* A reciprocating blade cutting tool, such as ’FEIN
Special Cutter’, is recommended for this operation. A
flat blade, with an effective length of at least 25mm
and a ’U’ shaped blade of at least 30mm is required.
CAUTION: Extreme care is necessary to
ensure that paintwork and trim does not
become damaged during the removal
process.
Particular care should be taken when using
cutting wire and handles to avoid damage to seal
along leading edge of fascia.
WARNING: Wear protective gloves when
handling glass, solvents and primers.
Remove
1. Remove interior mirror.
See this section.
2. Remove plenum panels.
See HEATING AND
VENTILATION, Repair.
3. Insert a thin plastic strip, such as a credit card,
between windcreen upper finisher and roof
panel.
4. Disengage 8 clips securing upper finisher by
sliding clips towards left hand side of vehicle.
5. Remove upper screen finisher.
76
CHASSIS AND BODY NEW RANGE ROVER
74
REPAIR
6. If fitted, disconnect heating element multiplugs.
Disconnect heating element earth wire. Tape
heater connections onto windscreen to prevent
fouling during removal procedure.
7. Mask around windscreen aperture to protect
paintwork.
8. Fit protective cover over fascia and bonnet.
Removal Using Reciprocating Blade Tool
9. Cut through P.U. adhesive along sides of screen
using flat blade.
10. Using a ’U’ shaped blade, cut through adhesive
bead along upper and lower edges of screen.
CAUTION: Access to adhesive around
lower screen supports is restricted.
Manoeuvre blade to cut as much sealant
from around screen supports as possible.
11. Attach suction lifters to glass. With assistance,
cut through remaining sealant around screen
supports using a sharp knife.
12. With assistance, remove windscreen glass.
Removal Using Cutting Wire and Handles.
13. Remove both ’A’ post finishers.
See this
section.
14. Remove both sun visors.
See this section.
15. Remove map/courtesy lamp assembly.
See
ELECTRICAL, Repair.
CHASSIS AND BODY
75
REPAIR
16. Mask along leading edge of headlining.
17. Using a sharp knife, cut through P.U. sealer at
side of screen, towards lower corner.
18. Insert cutting wire through knife cut and fit
handles, as shown, with approximately 200 mm
(8 in) of wire between handles.
19. With assistance, wedge tube of handle ’A’
between glass and body, ahead of the cutting
position, and carefully cut the sealer using a
continuous pull on handle ’B’ from the outside.
Cut side and top edges first. Attach suction lifters
and restrain glass as last of sealant is cut.
NOTE: When cutting along lower edge,
manoeuvre wire between glass edge and
screen supports to reduce strain on wire.
20. Attach suction lifters to glass. With assistance,
remove windscreen.
Refit
21. carefully cut old sealer from body flange to
obtain a smooth surface, approximately 2 mm
(1/16 in) thick.
CAUTION: Do not cut down to painted
surface.
22. Inspect supports, renew if damaged.
23. Position screen on felt covered surface.
24. If original screen is to be refitted, cut old sealer
from glass to obtain a smooth surface,
approximately 2 mm (1/16 in) thick.
76
CHASSIS AND BODY NEW RANGE ROVER
76
REPAIR
CAUTION: Do not cut down to surface of
glass.
25. Position and centralise new windscreen to body.
Apply tape reference marks to aid final fitment.
Remove screen and position to work surface.
26. Apply cleaning solvent to sealing surface of
glass and body flange.
CAUTION: Do not touch cleaned or primed
areas with fingers.
27. Position 5 screen spacer blocks on inside edge
of glass, over cut-out marks in obscuration band.
28. If necessary, peel off backing strip and stick
foam glazing dam along inside surface of glass,
approximately 13 mm (1/2 in) from top edge.
29. Shake primer tins for at least 30 seconds. Apply
body primer to sealing surface of body flange
using supplied applicator.
30. Apply glass primer to sealing surface of glass.
CAUTION: Use a separate applicator for
each primer.
31. Remove lid from sealer cartridge, remove
crystals, pierce membrane and fit pre-cut nozzle.
Fit cartridge to applicator gun.
NOTE: The profile of the nozzle must be
modified slightly to produce the required
bead section.
CHASSIS AND BODY
77
REPAIR
32. Apply a continuous bead of sealer to windscreen
as shown.
33. Fit suction lifters to glass.
34. With assistance, position glass centrally, using
previously made tape markings and lower onto
supports. Seat glass to spacer blocks.
CAUTION: Do not apply heavy pressure to
the sides of the screen. Lightly press
screen from centre outwards until edges
are to required gap. Pushing screen edges into
position can bend screen and lead to cracking in
service.
35. Remove protection from fascia and bonnet.
36. Remove masking tape.
37. If fitted, connect heating element multiplugs and
earth wire.
38. Remove clips from upper screen finisher.
39. Fit clips to body studs. Position upper screen
finisher and engage to clips.
40. Fit plenum panels.
See HEATING AND
VENTILATION, Repair.
41. Fit interior mirror.
See this section.
If Cutting Wire and Handles Used
42. Remove masking from leading edge of
headlining.
43. Fit map/courtesy lamp assembly.
See
ELECTRICAL, Repair.
44. Fit sun visors.
See this section.
45. Fit ’A’ post finishers.
See this section.
CAUTION: A curing time of 6 hours is
recommended. During this time, leave the
windows open and DO NOT slam the
doors.
76
CHASSIS AND BODY NEW RANGE ROVER
78
REPAIR
WINDSCREEN LOWER FINISHER
Service repair no - 76.43.41
Remove
1. Remove both windscreen side finishers.
See
this section.
2. Remove both windscreen wiper arms.
See
WIPERS AND WASHERS, Repair.
3. Release 10 clips securing windscreen lower
finisher.
4. Remove windscreen lower finisher.
Refit
5. Reverse removal procedure.
WINDSCREEN SIDE FINISHER
Service repair no - 76.43.39
Remove
1. Lift side finisher seal to reveal fixings.
2. Remove 4 screws securing side finisher.
3. Remove side finisher.
Refit
4. Position side finisher. Secure side with screws.
CHASSIS AND BODY
79
REPAIR
BACKLIGHT GLASS
Service repair no - 76.81.10
NOTE: The following equipment is
required:
masking tape.
Sharp knife.
Cutting wire and handles, or a reciprocating
blade, powered cutting knife*.
Suction lifters.
Windscreen repair kit.
Sealer applicator gun.
*A reciprocating blade cutting tool, such as ’FEIN
Special Cutter’ is recommended for this operation. A
flat blade, with an effective length of at least 25mm
and a ’U’ shaped blade of at least 30mm are required.
WARNING: Wear protective gloves when
handling glass, solvents and primers.
Remove
1. Remove interior trim from tailgate,
See this
section.
2. Release backlight lower finisher from 7 clips.
3. Remove backlight lower finisher.
4. Remove backlight side finishers.
NOTE: Side finishers are secured to
backlight with P.U. sealer. New backlight
glasses are supplied with side finishers
fitted. Side finishers are available separatley if
original glass is to be refitted.
5. Remove rubber finisher from upper edge of
backlight glass.
6. Protect tailgate panel with masking tape.
7. Disconnect two Lucar terminals from screen
heater element.
Removal Using Reciprocating Blade Tool
8. Cut through P.U. adhesive along sides of screen
using flat blade.
9. Using a ’U’ shaped blade, cut through adhesive
bead along upper and lower edges of glass.
CAUTION: Access around lower clips is
restricted. Manoeuvre blade to cut through
as much adhesive as possible.
10. Attach suction lifters to glass. With assistance,
cut through remaining sealant around lower
clips.
11. With assistance, remove backlight glass.
76
CHASSIS AND BODY NEW RANGE ROVER
80
REPAIR
Removal Using Cutting Wire Handles
12. Using a sharp knife, cut through P.U. sealer at
side of backlight.
13. Insert cutting wire through knife cut and fit
handles, as shown, with approximatley 200mm
of wire between handles.
14. With assistance, wedge tube of handle ’A’
between glass and body, ahead of the cutting
position, and carefully cut the sealer using a
continuous pull on handle ’B’ from the outside.
Cut side and top edges first. Attach suction lifters
and restrain glass as last of sealant is cut.
NOTE: When cutting along lower edge,
manoeuvre wire between glass edge and
finisher clips to reduce strain on wire.
15. With assistance, remove backlight glass.
Refit
16. Carefully cut old sealer from body flange to
obtain a smooth surface, approximately 2mm
thick.
CAUTION: Do not cut down to painted
surface.
17. Renew broken finisher clips as necessary.
Position finisher clips centrally on tailgate studs.
NOTE: Clips control height and seating of
lower glass edge.
18. Position and centralize new backlight to tailgate.
Apply tape reference mark to aid final fitment.
19. Position new backlight on felt covered surface.
20. Fit and centralize rubber finisher to top of glass.
NOTE: Finisher controls seating depth of
glass top edge.
21. Apply cleaning solvent to sealing surface of
glass and body flange.
CAUTION: Do not touch cleaned or primed
areas with fingers.
22. Shake primer tins for at least 30 seconds. Apply
body primer to sealing surface of body flange
using supplied applicator.
23. Apply glass primer to sealing surface of glass.
CAUTION: Use a separate applicator for
each primer.
24. Remove lid from sealer cartridge, remove
crystals, pierce membrane and fit pre-cut nozzle.
Fit cartridge to applicator gun.
NOTE: The profile of the nozzle must be
modified slightly to produce the required
bead section.
CHASSIS AND BODY
81
REPAIR
25. Apply a continuous bead of sealer to backlight
as shown.
26. Original glass:Apply 3mm bead of sealer to
channels of side finishers and fit to backlight.
27. Fit suction lifters to glass.
28. With assistance, fit glass and centralize to
previously made tape markings. Set glass to
correct depth.
29. Connect screen heater.
30. Remove reference and protective tapes.
31. Position lower finisher and secure to clips.
32. Fit interior trim to tailgate,
See this section.
CAUTION: A curing time of 6 hours is
recommended. During this time, leave the
windows open and DO NOT slam the
doors.
REAR QUARTER LIGHT
Service repair no - 76.81.20
NOTE: The following equipment is
required:
Masking tape.
Sharp knife.
Cutting wire and handles, or a reciprocatig
blade, powered cutting knife*.
Suction Lifters.
Windscreen repair kit.
Sealer applicator gun.
*A reciprocating blade cutting tool, such as ’FEIN
Special Cutter’ is recommended for this operation. A
flat blade, with an effective length of at least 25mm
and a ’U’ shaped blade of at least 30mm is required.
NOTE: New rear quarter glass is supplied
with exterior trim fitted.
WARNING: Wear protective gloves when
handling glass, solvents and primers.
Remove
1. Remove parcel tray support,
See this section.
2. Remove both ’E’ post trims,
See this section.
3. Remove relevant ’B’ post upper trim,
See this
section.
4. Remove relevant side interior lamp assembly,
See ELECTRICAL, Repair.
5. Remove relevant grab handle,
See this
section.
6. Remove relevant exterior ’E’ post finisher,
See
this section.
76
CHASSIS AND BODY NEW RANGE ROVER
82
REPAIR
7. Remove 2 trim studs securing headlining to ’E’
posts.
8. Release headlining from tailgate seal. Lower
headlining as necessary during glass removal to
provide access to sealant along top edge of
glass.
9. Disconnect aerial amplifier plugs.
10. R.H. glass only:Disconnect alarm receiver plug.
11. Protect surrounding area of body using masking
tape.
Removal Using Reciprocating Blade Tool
12. Lift flip seal to reveal trim fixings.
13. Remove 2 screws securing exterior trim to ’D’
post.
14. Cut through P.U. adhesive from inside of glass
along lower and side edges.
CHASSIS AND BODY
83
REPAIR
CAUTION: Manoeuvre knife blade around 3
parcel tray support clips. Ensure aerial
amplifier and alarm reciever plugs do not
become damaged.
15. Attach suction lifters to glass. With assistance,
cut through sealant along top of edge glass.
16. Remove rear quarter glass.
Removal Using Cutting Wire Handles
17. Protect surrounding area of body using masking
tape.
18. Lift flip seal to reveal trim fixings.
19. Remove 2 screws securing exterior trim to ’D’
post.
20. Carefully cut through adhesive bead between
glass and trim using a sharp knife.
NOTE: A reciprocating blade cutting tool,
such as ’FEIN Special Cutter’ will ease the
removal of the trim. Use a cranked blade
with an effective length of not more than 22mm.
21. Remove and discard quarter light trim.
NOTE: Rear quarter lights are supplied
with finisher fitted. Finisher is not
available separately.
22. Using a sharp knife, cut through P.U. sealer at
forward edge of quarter glass.
23. Insert cutting wire through knife cut and fit
handles, as shown, with approximatley 200mm
of wire between handles.
24. With assistance, wedge tube of handles ’A’
between glass and body, ahead of the cutting
position, and carefully cut the sealer using a
continuous pull on handle ’B’ from the outside.
Cut side and top edges first. Attach suction lifters
as last sealant is cut.
NOTE: When cutting along lower edge,
manoeuvre wire between glass edge and
parcel tray support clips to reduce strain
on wire.
CAUTION: Ensure aerial amplifier and
alarm receiver plugs do not become
damaged.
25. Remove rear quarter glass.
76
CHASSIS AND BODY NEW RANGE ROVER
84
REPAIR
Refit
26. Carefully cut old sealer from body flange to
obtain a smooth surface, approximatley 2mm
thick.
CAUTION: Do not cut down to painted
surface.
27. Position new quarter glass on felt covered
surface.
28. Apply cleaning solvent to sealing surface of
glass and body flange.
CAUTION: Do not touch cleaned or primed
areas with fingers.
29. Stick 4 self adhesive spacers on the inside edge
of glass at corners.
30. Shake primer tins for at least 30 seconds. Apply
body primer to sealing surface of body flange
using supplied applicator.
31. Apply glass primer to sealing surface of glass.
CAUTION: Use a separate applicator for
each primer.
32. Remove lid from sealer cartridge, remove
crystals, pierce membrane and fit pre-cut nozzle.
Fit cartridge to applicator gun.
NOTE: The profile of the nozzle must be
modified slightly to produce the required
bead section.
33. Apply a continuous bead of sealer to rear quarter
glass as shown.
34. Fit suction lifters to glass.
35. With assistance, fit glass and align to body. Seat
glass to spacer rubbers.
36. Remove protective tape.
37. Secure exterior trim to ’D’ post with screws.
38. Connect aerial amplifier plug.
39. R.H. glass only:Connect alarm receiver plug.
40. Position headlining and engage beneath tailgate
flip seal.
41. Secure headlining to ’E’ posts with trim studs.
42. Fit exterior ’E’ post finisher,
See this section.
43. Fit grab handle,
See this section.
44. Fit side interior lamp assembly,
See
ELECTRICAL, Repair.
45. Fit ’B’ post upper trim,
See this section.
46. Fit ’E’ post trims,
See this section.
47. Fit parcel tray support,
See this section.
CAUTION: A curing time of 6 hours is
recommended. During this time, leave the
windows open and DO NOT slam the
doors.
PANEL REPAIRS
1
SEALING AND CORROSION PROTECTION
CORROSION PROTECTION
Factory Treatments
The New Range Rover is treated with the following
anti-corrosion materials in production:
• A PVC-based underbody sealer material
which is sprayed onto the underfloor, wheel
arches and undersill areas.
• An application of cavity wax which is
sprayed into enclosed cavities, box
sections and lower inner door panels.
• A final coating of underbody wax to cover
the complete underfloor including
components but excluding brake discs.
• A coat of protective lacquer or wax applied
to the engine bay area.
In addition to the above measures, all steel parts are
zinc-coated both sides, and front wings, door and
tailgate skins are manufactured from aluminium.
The information given on the following pages is
intended as a guide and shows the areas to be
treated with cavity wax, as well as the access holes
used during manufacture. See GENERAL
INFORMATION DATA, Sealing and corrosion
protection section.
Underbody Wax
A coat of underbody wax is applied to the entire
underbody inboard of the sill vertical flanges, and
covers all moving and flexible components EXCEPT
for wheels and tyres, brakes and exhaust. The wax is
applied over paints and underbody sealers.
The underbody wax must be reinstated following all
repairs affecting floor panels.
CAUTION: Old underbody wax must be
completely removed from a zone
extending at least 200mm (7.9in.) beyond
the area where new underbody sealer is to be
applied.
Underbody Sealer
Underfloor areas and outer sill panels are treated with
a Plastisol PVC underbody sealer. This material is not
suitable for re-treatment.
When repairing areas of underbody sealer, strip the
factory-applied material back to a suitable break point,
ensuring that a clean metal surface is exposed and
that the edge of the existing material adheres soundly
to the panel.
Blanking plugs and grommets in the floor pan (except
those used for wax injection) MUST be fitted before
underbody sealer application. Heat-fusible plugs
which have been disturbed should either be refitted
with the aid of a hot air blower or replaced with rubber
grommets.
NOTE: Application of new underbody
sealer must be carried out between primer
and surfacer paint operations. Areas
where seam sealer is used should be re-treated as
necessary before application of underbody sealer.
CAUTION: Ensure that suspension units,
wheels, tyres, power unit, driveshafts,
exhaust and brakes (including all
mounting points) are shielded prior to application
of fresh underbody sealer.
Engine Bay Wax
Reinstate protective engine bay wax disturbed during
repairs using the approved material.
77
PANEL REPAIRS NEW RANGE ROVER
2
SEALING AND CORROSION PROTECTION
Stone Chip Resistant Paint/Primer
Re-treat all areas protected with factory-applied
anti-chip primer with suitable approved material in
repair.
Inspections during Maintenance Servicing
It is a requirement of the Land Rover Corrosion
Warranty that the vehicle body is checked for
corrosion by an authorised Land Rover dealer at least
once a year, to ensure that the factory-applied
protection remains effective.
Service Job Sheets include the following operations to
check bodywork for corrosion:
• With the vehicle on a lift, carry out visual
check of underbody sealer for damage.
• With the vehicle lowered, inspect exterior
paintwork for damage and body panels for
corrosion.
NOTE: Wash the vehicle and ensure that it
is free from deposits prior to inspection. It
is part of the owner’s responsibility to
ensure that the vehicle is kept free of
accumulations of mud which could accelerate the
onset of corrosion. The Dealer MUST wash the
vehicle prior to inspection of bodywork if the
customer has offered it in a dirty condition, and
pay special attention to areas where access is
difficult.
NOTE: The checks described above are
intended to be visual only. It is not
intended that the operator should remove
trim panels, finishers, rubbing strips or sound
deadening materials when checking the vehicle
for corrosion and paint damage.
With the vehicle on a lift, and using an inspection or
spot lamp, visually check for the following:
• Corrosion damage and damaged
paintwork, condition of underbody sealer
on front and rear lower panels, sills and
wheel arches.
• Damage to underbody sealer on main floor
and chassis members. Corrosion in areas
adjacent to suspension mountings and fuel
tank fixings.
NOTE: The presence of small blisters in
PVC underbody sealer is acceptable,
providing they do not expose bare metal.
Special attention must be paid to signs of damage
caused to panels or corrosion material by incorrect
jack positioning.
It is essential to follow the correct jacking and lifting
procedures. See GENERAL INFORMATION DATA,
Information section.
With the vehicle lowered, visually check for evidence
of damage and corrosion on all painted areas, in
particular the following:
• Front edge of bonnet.
• Visible flanges in engine compartment and
boot.
• Lower body and door panels.
Where bodywork damage or evidence of corrosion is
found during inspection, rectify this as soon as is
practicable, both to minimise the extent of the damage
and to ensure the long term effectiveness of the
factory-applied corrosion protection treatment. Where
the cost of rectification work is the owner’s
responsibility, the Dealer must advise the owner and
endorse the relevant documentation accordingly.
Where corrosion has become evident and is
emanating from beneath a removable component
(e.g. trim panel, window glass, seat etc.), remove the
component as required to permit effective rectification.
PANEL REPAIRS
3
SEALING AND CORROSION PROTECTION
Underbody Protection Repairs
When body repairs are carried out, always ensure that
full sealing and corrosion protection treatments are
restored. This applies both to the damaged area, and
also to areas where protection has been indirectly
impaired as a result of accident damage or repair
operations.
Prior to straightening out or panel beating, remove all
corrosion protection material in the damaged area.
This applies in particular to panels coated with wax,
PVC underbody sealer, sound deadening pads etc.
WARNING: DO NOT use oxy-acetylene gas
equipment to remove corrosion prevention
materials. Large amounts of fumes and
gases are liberated by these materials when they
burn.
Equipment for the removal of tough anti-corrosion
sealers offers varying degrees of speed and
effectiveness. The compressed air-operated scraper
(NOT an air chisel) offers a relatively quiet mechanical
method of removal using an extremely rapid
reciprocating action. During use, direct the operating
end of the tool along the work surface.
The most common method is by the use of a hot air
blower with integral scraper.
CAUTION: High temperatures can be
generated with this equipment which may
cause fumes. Always exercise care in its
use.
Another tool, and one of the most efficient methods, is
the rapid-cutting ’hot knife’. This tool uses a wide
blade and is quick and versatile, able to be used
easily in profiled sections where access is otherwise
awkward.
Use the following procedure when repairing
underbody coatings:
1. Remove existing underbody coatings.
2. After panel repair, clean the affected area with a
solvent wipe, and treat bare metal with an etch
phosphate material.
3. Re-prime the affected area. DO NOT under any
circumstances apply underbody sealer
directly to bare metal surfaces.
4. Replace all heat-fusible plugs which have been
disturbed. Use rubber grommets of equivalent
size if plugs are not available, but ensure that
they are embedded in sealer.
5. Mask off all mounting faces from which
mechanical components, hoses and pipe clips,
have been removed. Underbody sealer must be
applied before such components are refitted.
6. Brush sealer into all exposed seams.
7. Spray the affected area with an approved
service underbody sealer.
8. Remove masking from component mating faces,
and touch-in where necessary. Allow adequate
drying time before applying underbody wax.
Underbody Wax
After refitting mechanical components, including
hoses, pipes and small fixtures, mask off the brake
discs and apply a coat of approved underbody wax.
NOTE: Where repairs include the
application of finish paint coats in the
areas requiring underbody wax, paint
operations must be carried out BEFORE wax
application.
Underbonnet Wax
Where repairs have involved replacement of engine
bay panels, treat the entire engine compartment
including all components, clips and small fixtures with
an approved underbonnet lacquer or wax.
Proprietary Anti-Corrosion Treatments
The application of proprietary anti-corrosion
treatments in addition to the factory-applied treatment
could invalidate the Corrosion Warranty and should be
discouraged. This does not apply to approved,
compatible, preservative waxes which may be applied
on top of existing coatings.
77
PANEL REPAIRS NEW RANGE ROVER
4
SEALING AND CORROSION PROTECTION
Fitting Approved Accessories
When fitting accessories it is important that the
vehicle’s corrosion protection is not affected, either by
breaking the protective coating or by introducing a
moisture trap.
DO NOT screw self-tapping screws directly into the
body panel but fit plastic inserts first. Protect the
edges of holes drilled into panels, chassis members
and other body parts with a suitable zinc rich or acid
etch primer, followed by a protective wax coating
brushed onto the surrounding area.
DO NOT affix unpainted metal surfaces of any
accessory directly to the vehicle bodywork unless they
are suitably protected. Where metal faces are bolted
together always interpose a suitable interface material
such as weldable zinc rich primer, extruded strip or
zinc tape.
Cavity Wax Injection
Box sections treated with cavity wax are shown in this
section. Repairs affecting these areas must include
re-treatment with an approved cavity wax, using the
access points ilustrated. In addition, all interior
surfaces which have been disturbed during repairs
must be wax injected whether they have been treated
in production or not. This includes all box members,
cavities, door interiors etc. It is permissible to drill
extra holes for access where necessary, provided
these are not positioned in load-bearing members.
Ensure that such holes are treated with a suitable zinc
rich primer, brushed with wax and then sealed with a
rubber grommet.
Prior to wax injection, ensure that the cavity to be
treated is free from any contamination or foreign
matter. Where necessary, clear out any debris using a
compressed air supply.
Carry out wax injection after final paint operations.
During application, ensure that the wax covers all
flange and seam areas and that it is applied to all
repaired areas of both new and existing panels.
NOTE: Apply cavity wax AFTER the final
paint process and BEFORE refitting of any
trim components.
It should also be noted that new panel assemblies and
body shells are supplied without wax injection
treatment which must be carried out after repairs.
Effective cavity wax protection is vital. Always observe
the following points:
• Complete all finish paint operations before
wax application.
• Clean body panel areas and blow-clean
cavities if necessary, before treatment.
• Maintain a temperature of 18˚ C during
application and drying.
• Check the spray pattern of injection
equipment.
• Mask off all areas not to be wax coated
and which could be contaminated by wax
overspray.
• Remove body fixings, such as seat belt
retractors, if contamination is at all likely.
• Move door glasses to fully closed position
before treating door interiors.
• Treat body areas normally covered by trim
before refitting items.
• Check that body and door drain holes are
clear after the protective wax has dried.
• Keep all equipment clean, especially wax
injection nozzles.
PANEL REPAIRS
5
SEALING AND CORROSION PROTECTION
Application Equipment and Techniques
1. Air inlet
2. Flow control (spray pattern adjustment)
3. Pressure cup (1 litre [1.7pt.] capacity). Maximum
pressure 140PSI (9.7 bar, 9.8kg/cm
2
).
4. Gun connector
5. Lance nipple connection
6. Flexible lance
7. Rigid directional hook wand (forward cone spray
pattern)
8. Flexible nylon 1100mm (43.3in.) lance with 360Ëš
spray pattern
9. Rigid 1100mm (43.3in.) lance with 360Ëš spray
pattern
When re-treating wax-injected areas which have been
disturbed during repairs, it is necessary to use a
compressed air spray gun with integral pressure cup
and a selection of interchangeable lances.
The following points must be observed during use,
according to the attachments fitted:
• Use the rigid or flexible lance attachments
with 360Ëš spray dispersal when treating
enclosed areas, to ensure maximum
coverage.
• Where openings are restricted, use the
hook nozzle to provide a more directional
spray (e.g. inside narrow or short box
sections).
• Spray exposed underbody surfaces directly
from the gun less lance attachment and
without disconnecting the fluid coupling.
1100 mm (43.3in.) Rigid Lance:The nozzle on the
rigid lance produces a 360Ëš circular spray pattern
combined with a forward-directed spray. Although wax
is distributed to all box section surfaces in a single
stroke, effective and complete coverage is best
achieved in long, straight structures and box section
cavities by spraying on both outbound and return
strokes of the lance.
The rigid lance also provides the positional accuracy
required in shaped sections, by allowing visual
assessment.
CAUTION: Do not force the lance into
access holes when using this attachment.
1100 mm (43.3in.) Flexible Nylon Lance:This lance
is similar in pattern to the rigid version, but provides
the additional penetration needed for curved sections
or in places where access is difficult. Its main
limitation is a lack of positional accuracy inside box
sections.
Carry out spraying on the outward stroke of the lance.
Withdraw the lance slowly to ensure sufficient
coverage. DO NOT withdraw the lance too quickly.
Keep the nylon tube of the lance away from the edges
of the access hole to eliminate abrasion and extend
the life of the tube. Take care to ensure that spraying
ceases just before the nozzle emerges from the
access hole. To assist this process, apply RED paint
to the final 30mm (1.2in.) of the nozzle.
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PANEL REPAIRS NEW RANGE ROVER
6
SEALING AND CORROSION PROTECTION
Hook Nozzle on Flexible Lance:The rigid hook
produces a highly atomised, forward-directed, fully
conical spray pattern having long range and good
dispersion characteristics. This combination has good
directional capabilities for the treatment of short,
narrow sections and may also be used for direct
spraying of inner wheelarches etc.
Position the flat area at the end of the lance at 180Ëš to
the nozzle spray direction. This will help to guide the
spray more accurately when it is concealed in a box
section or access hole.
For general spraying move the nozzle in an arc from
side to side, to ensure full coverage.
NOTE: Keep all wax injection/application
equipment clean. Use white spirit for this
purpose immediately after wax injection
operations.
Precautions during Body Repairs and Handling
Take care when handling the vehicle in the workshop.
PVC underbody sealers, seam sealers, underbody
wax and body panels may be damaged if the vehicle
is carelessly lifted.
Always follow the correct lifting, jacking and towing
procedures as shown in GENERAL INFORMATION
DATA, Information section, paying particular
attention to the following points:
• Locate trolley jack pads properly before
lifting and lower the jack fully before
withdrawal.
• Use only the approved hoisting points
when overhead hoisting is required.
• Locate the lifting heads of wheel-free lifts
correctly, with rubber or similar material
placed between lifting head and
underbody.
Steam Cleaning and Dewaxing
Due to the high temperatures generated by steam
cleaning equipment, there is a risk that certain trim
items could be damaged and some adhesives and
corrosion prevention materials softened or liquified.
Adjust the equipment so that the nozzle temperature
does not exceed 90Ëš C (194Ëš F). Take care not to
allow the steam jet to dwell on one area, and keep the
nozzle at least 300mm (11.8in.) from panel surfaces.
Do NOT remove wax or lacquer from underbody or
underbonnet areas during repairs. Should it be
necessary to steam clean these areas, apply a new
coating of wax or underbody protection as soon as
possible.
PANEL REPAIRS
7
SEALING AND CORROSION PROTECTION
CAVITY WAX
1. Injection hole at lower ’A’ post.
2. Injection hole at lower ’B’ post.
All areas symmetrically opposite to those shown are also treated.
See GENERAL INFORMATION DATA, Information section.
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PANEL REPAIRS NEW RANGE ROVER
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SEALING AND CORROSION PROTECTION
SEALANTS AND ADHESIVES
Structural Adhesive
Metal-to-metal adhesive is applied to critical joint
areas during factory assembly. The material used is a
high-temperature, heat cured, nitrile phenolic which
serves both to bond two metal surfaces and also to
seal the joint against ingress of dust, water, petrol and
fumes. This material is not suited for service use, and
should be substituted in repair using a suitable
medium strength adhesive.
When separating a joint treated with metal-to-metal
adhesive, to avoid distortion it is recommended that
the joint be gently heated until the bonds weakens
sufficiently to permit panel separation.
NOTE: Spot welding through
metal-to-metal adhesive is feasible, but
take special care to adjust the transformer
setting to ensure a reliable weld. DO NOT carry
out MIG welding on a joint area which has been
treated with metal-to-metal adhesive until all
traces of adhesive have been removed.
Seam Sealers
A heat cured, PVC Plastisol sealer is applied to joint
areas during factory assembly. This material is not
suitable for service use.
Carry out seam sealing after the application of primer
and before the surfacer and final paint coats. Ensure
that surfaces are first cleaned of all grease and oil.
Apply the sealer material to the joint as a bead, either
by hand or using an applicator gun. Brush sealer well
into the joint and wipe smooth using a cloth soaked
with solvent such as Shell SBP3. This will ensure an
acceptable cosmetic finish.
Apply sealer to ALL accessible joints following repair
work. Be aware that damage to a vehicle can often
result in deflection to those areas of the body which
are remote from the impact. The sealers in these
areas can therefore be disturbed by subsequent
straightening and repair operations. Check joints in
the vicinity of the area undergoing repair for evidence
of cracked sealer, clean them out as required and
re-treat them with fresh sealer using the following
procedure:
• Clean the affected joint or seam and
re-treat any exposed metal areas with a
suitable etch phosphate primer.
• Treat affected area with an acid-etch
primer.
• Apply appropriate seam sealer as
necessary.
• Apply appropriate colour coat (and
underbody sealer as applicable).
Where joints are inaccessible following the
reassembly or fitment of components, ensure that a
paste-type sealer is applied to such joints. Certain
seams also become inaccessible after the completion
of panel repairs. In such instances the paint process
should be carried out and sealers applied before final
assembly.
Provided access is adequate, apply the sealer to both
sides of the repair joint. Where access is limited to
one side only (e.g. box sections), inject the affected
box member with cavity wax.
CAUTION: ALWAYS deploy an extractor
unit to remove toxic fumes when using
oxy-acetylene equipment to remove panels
treated with wax and sealers.
PANEL REPAIRS
9
SEALING AND CORROSION PROTECTION
Sealing Water Leaks
Sealing charts in this section show those areas of the
bodyshell most likely to be affected by accident
damage and water leaks, and which could therefore
require re-treatment in repair. They do not show those
joint areas which only apply to factory assembly
operations and which are unlikely to be disturbed in
service (e.g. centre tunnel), or where the damage
would be so severe that the entire bodyshell would
normally be written off.
When water leakage occurs, always adopt a logical
approach to the problem using a combination of skill,
experience and intuition. Do not attempt to reach a
conclusion based only on visual evidence, such as
assuming that a leak emanates from the windscreen
because the footwell is wet. It will often be found that
the source of the leak is elsewhere. The correct
procedure will increase the chance of locating a leak,
however obscure it may seem.
Tools and Equipment
The following tools and equipment are recommended
for detection and rectification of water leaks:
1. Garden sprayer (hand-operated).
2. Wet/dry vacuum cleaner.
3. Dry absorbent cloths.
4. Battery torch.
5. Small mirror.
6. Weatherstrip locating tool.
7. Trim panel remover.
8. Small wooden or plastic wedges.
9. Dry compressed air supply.
10. Hot air blower.
11. Sealer applicators.
12. Ultrasonic leak detector.
During leak detection, the vehicle should be
considered in three basic sections:
• The front interior space,
• The rear passenger space (where
applicable), and
• The rear loadspace or boot.
Testing
From the information supplied by the customer it
should be possible for the bodyshop operator to locate
the starting point from which the leak may be
detected. After the area of the leak has been
identified, find the actual point of entry into the vehicle.
A simple and effective means initially is an ordinary
garden spray with provision for pressure and jet
adjustment. This will allow water to be directed in a jet
or turned into a fine spray. Use a mirror and a
battery-powered torch (NOT a mains voltage
inspection lamp) to see into dark corners.
The sequence of testing is particularly important. Start
at the lowest point and work slowly upwards, to avoid
testing in one area while masking the leak in another.
For example, if testing started at the level of the
windscreen, any water cascading into the plenum
chamber could leak through a bulkhead grommet and
into the footwells. Even at this point it could still be
wrongly assumed that the windscreen seal was at
fault.
Another important part of identifying a water leak is by
visual examination of door aperture seals, grommets
and weatherstrips for damage, deterioration or
misalignment, together with the fit of the door itself
against the seals.
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PANEL REPAIRS NEW RANGE ROVER
10
SEALING AND CORROSION PROTECTION
Sealing
When the point of the leak has been detected,
proceed to rectify it using the following procedure:
1. Renew all door aperture seals and weatherstrips
which have suffered damage, misalignment or
deterioration.
2. Check all body seals to ensure that they are
correctly located on their mounting flanges/faces
using a locating tool if necessary.
3. Dry out body seams to be treated using
compressed air and/or a hot air blower as
necessary.
4. Apply sealant on the outside of the joint
wherever possible to ensure the exclusion of
water.
5. When rectifying leaks between a screen glass
and its weatherstrip (or in the case of direct
glazing, between the glass and bodywork), avoid
removing the glass if possible. Apply the
approved material either at the glass to
weatherstrip or glass to body.
PANEL REPAIRS
11
SEALING AND CORROSION PROTECTION
SEALING CHARTS
1. Structural adhesive
2. Structural adhesive
3. Structural adhesive
4. Structural adhesive
5. Structural adhesive, seam sealer
6. Structural adhesive, seam sealer
7. Semi-structural adhesive/anti-flutter material
8. Semi-structural adhesive/anti-flutter material
9. Semi-structural adhesive/anti-flutter material
10. Semi-structural adhesive/anti-flutter material
11. Structural adhesive
12. Structural adhesive
All areas symmetrically opposite to those shown are also treated.
see GENERAL INFORMATION DATA, Information section.
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PANEL REPAIRS NEW RANGE ROVER
12
SEALING AND CORROSION PROTECTION
13. Putty
14. Putty
15. Structural adhesive
16. Putty, seam sealer heavy
17. Putty, seam sealer heavy
18. Structural adhesive
19. Structural adhesive
20. Structural adhesive
21. Structural adhesive
All areas symmetrically opposite to those shown are also treated.
See GENERAL INFORMATION DATA, Information section.
PANEL REPAIRS
13
SEALING AND CORROSION PROTECTION
22. Structural adhesive
23. Semi-structural adhesive/anti-flutter material
24. Seam sealer light
25. Seam sealer light, structural adhesive
26. Seam sealer light
27. Seam sealer
28. Seam sealer
29. Seam sealer heavy
30. Seam sealer light
31. Seam sealer light
All areas symmetrically opposite to those shown are also treated.
See GENERAL INFORMATION DATA, Information section.
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PANEL REPAIRS NEW RANGE ROVER
14
SEALING AND CORROSION PROTECTION
34. Seam sealer light
35. Seam sealer light
36. Seam sealer light
37. Seam sealer light
All areas symmetrically opposite to those shown are also treated.
See GENERAL INFORMATION DATA, Information section.
PANEL REPAIRS
15
SEALING AND CORROSION PROTECTION
32. Brushable sealer
33. Seam sealer light
38. Seam sealer light
39. Seam sealer light
40. Seam sealer light
41. Seam sealer light
All areas symmetrically opposite to those shown are also treated.
See GENERAL INFORMATION DATA, Information section.
PANEL REPAIRS
1
PANELS
PAINT
Replacement Panels
Service panels are supplied with a cathodic primer
coating as part of the panel protection, and in
compliance with the vehicle’s Corrosion Warranty
where applicable. DO NOT remove this primer
before paint refinishing. In the event of localised
surface damage or imperfections, ensure that the
minimum of primer is removed during rectification
work for effective repair.
Rectify damage by panel beating or straightening. To
remove corrosion or paint runs on outer surfaces,
abrade primer coat in the affected area as necessary
using the following procedure:
1. Clean the panel using a solvent wipe.
2. Treat exposed areas of metal with an etch
phosphate process.
3. Re-treat the affected area using either a
separate acid-etch primer and two-pack
surfacer, or an integrated etch primer/filler.
Bolted Panels
Before fitting bolt-on panels, ensure that all mating
and adjacent surfaces on the vehicle and replacement
panel are free from damage and distortion. Rectify if
necessary as described in this section, and apply
preformed strip sealer where specified.
Welded Panels
1. Remove primer from the immediate vicinity of
new and existing panel flanges, cleaning to
bright metal finish.
2. On joints to be spot welded, apply weld-through
zinc rich primer to joint faces of both flanges.
Make spot welds while primer is still wet or
according to the manufacturer’s instructions.
3. Dress accessible weld seams.
4. Clean panel using solvent wipe.
5. Treat bare metal with an etch phosphate
process.
6. Re-treat repaired areas.
NOTE: It is not satisfactory to use
weld-through, zinc rich primers in
conjunction with arc or MIG welding.
Sectioned Panels
When replacing part or sectioned panels, the basic
procedure is the same as for welded panels described
above, with the following variations:
1. Remove primer from both new and existing joint
faces, cleaning to a bright metal finish.
2. Where an overlap joint with the existing panel is
to be spot welded, apply weld-through, zinc rich
primer to both joint faces and spot weld while the
primer is still wet or according to the
manufacturer’s instructions.
3. MIG weld butt joints where applicable.
4. Clean the panel with a solvent wipe.
5. Treat bare metal areas using an etch phosphate
process.
6. Re-prime affected areas as necessary as for
rectifying transit damage. See this section.
7. Treat the inner faces of lap or butt joints with a
suitable cavity wax. See Sealing and corrosion
protection.
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PANEL REPAIRS NEW RANGE ROVER
2
PANELS
Clinch Panels (eg Doorskins etc.)
1. Abrade primer on new and existing panel joint
faces, and clean using a solvent wipe.
2. Apply metal-to-metal adhesive where applicable.
3. Where joints are to be spot welded, apply
suitable weld-through, zinc rich primer to weld
areas.
4. Where joints are to be MIG, arc or gas welded,
apply zinc rich primer in adjacent areas but
leave the welded area untreated.
5. To retain the panel whilst clinching the flanges,
tack spot weld or plug weld as appropriate.
6. Clean the panel with a solvent wipe.
7. Treat bare metal areas with a suitable etch
phosphate process.
8. Re-prime affected areas as necessary as for
rectifying transit damage. See this section.
NOTE: Replacement doors, bonnets and
tailgates must be treated with a suitable
seam sealer on clinched seams, following
the primer coat.
Paint Refinishing
1. Seal all accessible exterior and interior seams
with an approved seam sealer. Certain joints
such as sill lower flange seams must be left
unsealed.
2. Apply a suitable anti-chip primer where
specified.
3. Apply a two-pack paint refinishing system.
4. Repair any damage to underbody sealers either
at this stage or before paint operations.
Paint Repairs
Before carrying out paintwork repairs, the vehicle
must be thoroughly cleaned using either a steam
cleaner or high-pressure washer.
Wash locally repaired areas using a mild
water-mixable detergent and wipe them clean with
solvent, immediately prior to paint application.
Abrade damaged paintwork where bare metal has
been exposed until the metal is clean and extends
beyond the area of immediate damage. Treat the bare
metal with an etch phosphate to remove all traces of
rust and provide a key for new paint coats. Re-treat
the affected area using either a separate acid-etch
primer and two-pack surfacer or an integrated etch
primer/filler, and follow with a two-pack paint system.
Those surfaces not receiving paint must be treated
with a cavity wax following paint operations.
A. Two-pack top coat
B. Two-pack primer filler and etch primer
C. Etch phosphate
PANEL REPAIRS
3
PANELS
SERVICE CONDITION OF PANELS
Bodyshell Assembly
Bodyshells, which are also supplied with sunroof
aperture (not shown), are serviced less front wings,
bonnet,door assemblies and upper/lower tailgates.
Headlamp and Grille Panel
Headlamp/grille panels are serviced as a complete
assembly including a bolt-on bonnet lock platform.
Front Wing
Front wings are serviced as separate bolt-on
aluminium panels.
Bonnet
Bonnets are serviced less hinges which are available
separately.
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PANEL REPAIRS NEW RANGE ROVER
4
PANELS
Valance and Wheelarch
Valance and wheelarch panels are serviced as a
separate part and are fitted to the bulkhead.
Front Sidemember
Front sidemembers are fitted to the ’A’ post and
valance/wheelarch.
’A’ Post Lower
The ’A’ post lower is fitted to the bulkhead, inner sill
and ’A’ post reinforcement.
’A’ Post Panels
’A’ posts are serviced as separate ’A’ post repair
panel (1), upper ’A’ post (2) and ’A’ post reinforcement
(3).
’B’ Post Panels
’B’ posts are serviced as separate ’BC’ post
reinforcement (1) and inner ’BC’ post panels (2, 3).
PANEL REPAIRS
5
PANELS
Door Assemblies and Outer Door Panels
Door assemblies comprise an aluminium outer panel
fitted to a steel frame.
’BC’ Post Repair Panel
’BC’ posts are serviced as a complete panel including
the sill.
Roof Assembly
Roof assemblies are serviced complete with inner
frames.
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PANEL REPAIRS NEW RANGE ROVER
6
PANELS
Outer Rear Quarter Panel
Outer rear quarters are serviced as a separate panel.
Lower Panel
Lower panels are serviced as an assembly including
the tailgate lock reinforcement.
Upper Tailgate Assembly
Upper tailgates are serviced less hinges, which are
available separately.
Lower Tailgate Assembly
Lower tailgate assemblies comprise an aluminium
outer panel fitted to a steel frame and are serviced
less hinges, which are available separately. Lower
tailgate outer panels are also serviced as separate
items.
PANEL REPAIRS
7
PANELS
Inner Rear Quarter Panel
Inner rear quarters are serviced as an assembly with
associated reinforcements and brackets.
Rear Crossmember Panel
The rear crossmember is serviced as a separate
panel.
Load Floor Side
Load floor sides are serviced as a separate panel.
Rear Crossmember Extension
The rear crossmember extension is serviced
separately.
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PANEL REPAIRS NEW RANGE ROVER
8
PANELS
Rear Quarter Repair Panel
The rear quarter which is fitted between the outer
panel and inner quarter is serviced as a separate
repair panel.
Spare Wheel Closing Panel
The spare wheel closing panel is serviced separately
and fits at the upper front of the spare wheel well.
PANEL REPAIRS
1
PROCEDURES
GENERAL WELDING PRECAUTIONS
For ease of reference the diagrams on the following
pages show only the type of weld used in repair where
this varies from that used in production.
When carrying out welding operations the following
criteria must be observed:
• Where resistance spot welds have been
used in production, these must be
reproduced with new spot welds in
replacement where possible. All such
reproduction spot welds must be spaced
30mm (1.2in.) apart.
• When spot welding, it is recommended that
test coupons of the same metal gauges
and materials are produced to carry out
peel tests to ensure that welding
equipment being used can produce a
satisfactory joint. Plug welds must be used
if a satisfactory spot weld cannot be
produced.
• The electrode arms on hand-held spot
welding guns must not exceed 300mm in
length.
• Single-sided spot welding is not
acceptable.
• Brazing and gas welding are not
acceptable EXCEPT where they have been
specified in production.
• Where 3 metal thicknesses or more are to
be welded together it is imperative to use
MIG plug welds to ensure joint strength.
• MIG plug welds must be used in repair
joints where there is no access for a
resistance spot welder. To replace each
production spot weld a hole must be drilled
and/or punched, and a MIG weld then
made in its place. The number of plug
welds must match exactly the number of
spot welds which have been removed.
• Where holes are left in an existing panel
after removal of the spot welds, a single
MIG plug weld will be made in each hole as
appropriate.
• The replacement welds in the welding
diagrams are denoted by the following
symbols:
A. Single thickness plug welds
B. Multiple thickness plug welds
C. MIG seam weld
Seat Belt Anchorages
Seat belt anchorages are safety critical. When making
repairs in these areas it is essential to follow design
specifications. Note that High Strength Low Alloy
(HSLA) steel may be used for seat belt anchorages.
Where possible, the original production assembly
should be used, complete with its seat belt
anchorages, or the cut line should be so arranged that
the original seatbelt anchorage is not disturbed.
All welds within 250mm (9.9in.) of seat belt
anchorages must be carefully checked for weld
quality, including spacing of spot welds.
WARNING: Body parts incorporating seat
belt anchorages MUST be renewed
completely if damaged beyond repair, as
the welds in these areas are safety critical and
cannot be disturbed.
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PANEL REPAIRS NEW RANGE ROVER
2
PROCEDURES
PANEL REPLACEMENT PROCEDURE
General
This information is designed to explain the basic panel
removal and replacement method. This standard
method may vary slightly from one vehicle to another.
The main criterion in removal and replacement of
body panels is that Land Rover’s original standard is
maintained as far as possible.
Remove Panel
1. Expose resistance spot welds. For those spot
welds which are not obviously visible, use a
rotary impregnated wire brush fitted to an air
drill, or alternatively a hand held wire brush.
NOTE: In wheelarch areas it may be
necessary to soften underbody coating
using a hot air gun, prior to exposing spot
welds.
2. Cut out welds using a cobalt drill.
3. Alternatively use a clamp-type spot weld
remover.
PANEL REPAIRS
3
PROCEDURES
4. Cut away the bulk of the panel as necessary
using an air saw.
NOTE: On certain panel joints MIG welds
and braze should be removed using a
sander where possible, before cutting out
the panel bulk.
5. Separate spot welded joints and remove panel
remnants using hammer, bolster chisel and
pincers.
Prepare Old Surfaces
6. Clean all panel joint edges to a bright smooth
finish, using a belt-type sander.
NOTE: Prior to sanding, remove remaining
sealant using a hot air gun to minimise the
risk of toxic fumes caused by generated
heat. CARE MUST BE TAKEN TO AVOID
EXCESSIVE HEAT BUILD UP WHICH MAY BE
CAUSED BY THIS EQUIPMENT.
7. As an alternative a disc sander may be used.
Straighten existing joint edges using shaping
block and hammer.
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PANEL REPAIRS NEW RANGE ROVER
4
PROCEDURES
Prepare New Surfaces
8. Mark out bulk of new panel and trim to size,
leaving approximately 50mm (1.9in.) overlap
with existing panel. Offer up new panel/section,
align with associated panels (e.g. new rear
quarter aligned with door and tailgate). Clamp
into position.
9. Cut new and existing panels as necessary to
form butt, joggle or brace joint as required.
Remove all clamps and metal remnants.
10. Prepare new panel joint edges for welding by
sanding to a bright finish. This must include inner
as well as outer faces.
11. Apply suitable weld-through primer to panel joint
surfaces to be welded, using brush or aerosol
can.
PANEL REPAIRS
5
PROCEDURES
12. Apply adhesive sealant to panel joint surfaces.
See GENERAL SPECIFICATION DATA,
Information section.
Offer Up and Align
Offer up new panel and align with associated panels.
Clamp into position using welding clamps or Mole
grips. Where a joggle or brace joint is being adopted,
make a set in the original panel joint edge or insert a
brace behind the joint.
NOTE: In cases where access for welding
clamps is difficult, it may be necessary to
use tack welds.
Welding
13. Select arms for resistance spot welding and
shape electrode tips using a tip trimmer.
NOTE: To maintain efficiency, the tips will
require regular cleaning with emery cloth.
CAUTION: Use electrode arms not
exceeding 300mm (11.8in.) in length.
14. Fit resistance spot welding arms and test
equipment for satisfactory operation, using test
coupons. Where monitoring equipment is not
available, verify weld strength by checking that
metal around the weld puddle pulls apart under
tension during pulling.
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PANEL REPAIRS NEW RANGE ROVER
6
PROCEDURES
15. Use a resistance spot welder where access
permits. Try to ensure weld quality by using a
weld monitor where possible.
16. MIG tack weld butt joints and re-check alignment
and panel contours where necessary. Ensure
that a gap is maintained to minimise welding
distortion, by inserting a hacksaw blade as an
approximate guide.
17. Dress MIG tack welds using a sander with 36 grit
disc, or a belt-type sander where access is
limited.
PANEL REPAIRS
7
PROCEDURES
18. MIG seam weld butt joints.
19. Always use MIG plug welds where excessive
metal thickness or lack of access make
resistance spot welding impractical. Make plug
welds either by using holes left by the spot weld
cutter, or through holes punched or drilled for the
purpose.
20. Dress all welds using a sander with 36 grit disc,
or a belt-type sander and/or impregnated wire
brush.
NOTE: Brazing operations, if required,
must be carried out at this point.
Body Trim
The following panel repair operations itemise body
trim components which must be removed for access
during each repair. See Repairs section.
Because of the unpredictable nature of accident
damage, the items listed make no allowance for any
difficulties which may be found in removal and only
apply to an undamaged vehicle. No allowance is
made for any difficulties which may be found during
panel removal. Damaged body trim items must be
renewed as necessary following body repairs.
PANEL REPAIRS
1
REPAIR
VALANCE AND WHEELARCH
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
5. Remove airbag modules.
See
SUPPLEMENTARY RESTRAINT SYSTEM,
Repair.
6. Disconnect alternator.
7. Remove front bumper valance.
See CHASSIS
AND BODY, Repair.
8. Remove extension spoiler front bumper.
See
CHASSIS AND BODY, Repair.
9. Remove front grille.
See CHASSIS AND BODY,
Repair.
10. Remove headlamp.
See Workshop Manual -
ELECTRICAL.
11. Remove bonnet.
See CHASSIS AND BODY,
Repair.
12. Remove bonnet strut.
See CHASSIS AND
BODY, Repair.
13. Remove bonnet lock RH or LH.
See CHASSIS
AND BODY, Repair.
14. Remove wheel arch liner - front.
See CHASSIS
AND BODY, Repair.
15. Remove front door assembly.
See CHASSIS
AND BODY, Repair.
16. Remove ’A’ post trim.
See CHASSIS AND
BODY, Repair.
17. Remove fascia.
See CHASSIS AND BODY,
Repair.
18. Remove front wing.
19. Remove engine.
See Workshop Manual -
ENGINE.
20. Remove gearbox.
See Workshop Manual -
GEARBOX.
Refit
NOTE: In this operation the valance and
wheelarch is fitted in combination with a
front sidemember.
21. Prepare and clean panel joint faces. Punch or
drill holes in new valance and wheelarch for plug
welding as shown.
22. Reverse removal procedure.
23. Remove stands and lower vehicle.
77
PANEL REPAIRS NEW RANGE ROVER
2
REPAIR
FRONT SIDEMEMBER
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
5. Remove airbag module.
See
SUPPLEMENTARY RESTRAINT SYSTEM,
Repair.
6. Disconnect alternator.
7. Remove front bumper valance.
See CHASSIS
AND BODY, Repair.
8. Remove extension spoiler front bumper.
See
CHASSIS AND BODY, Repair.
9. Remove front grille.
See CHASSIS AND BODY,
Repair.
10. Remove headlamp.
See Workshop Manual -
ELECTRICAL
11. Remove bonnet.
See CHASSIS AND BODY,
Repair.
12. Remove bonnet strut.
See CHASSIS AND
BODY, Repair.
13. Remove bonnet lock RH or LH.
See CHASSIS
AND BODY, Repair.
14. Remove wheel arch liner - Front.
See CHASSIS
AND BODY, Repair.
15. Remove front door assembly.
See CHASSIS
AND BODY, Repair.
16. Remove ’A’ post trim.
See CHASSIS AND
BODY, Repair.
17. Remove front wing.
Refit
18. Prepare and clean panel joint faces. Punch or
drill holes in new front sidemember for plug
welding as shown.
WARNING: Remove ALL traces of
adhesive from valance upper edge before
plug welding.
19. Reverse removal procedure.
20. Remove stands and lower vehicle.
PANEL REPAIRS
3
REPAIR
UPPER ’A’ POST PANEL AND REPAIR PANEL
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
5. Remove both airbag modules.
See
SUPPLEMENTARY RESTRAINT SYSTEM,
Repair. See SUPPLEMENTARY RESTRAINT
SYSTEM, Repair.
6. Disconnect alternator.
7. Remove front bumper valance.
See CHASSIS
AND BODY, Repair.
8. Remove extension spoiler front bumper.
See
CHASSIS AND BODY, Repair.
9. Remove front grille.
See CHASSIS AND BODY,
Repair.
10. Remove windscreen.
See CHASSIS AND
BODY, Repair.
11. Remove headlamp.
See Workshop Manual -
ELECTRICAL.
12. Remove bonnet.
See CHASSIS AND BODY,
Repair.
13. Remove wheel arch liner - front.
See CHASSIS
AND BODY, Repair.
14. Remove front door assembly.
See CHASSIS
AND BODY, Repair.
15. Remove ’A’ post trim.
See CHASSIS AND
BODY, Repair.
16. Remove fascia assembly.
See CHASSIS AND
BODY, Repair.
17. Remove front wing.
Refit
NOTE: In this operation, the ’A’ post panel
and repair panel are replaced in
combination with the lower ’A’ post and
reinforcement. It is also necessary to remove the
front sidemember for access.
18. Prepare and clean panel joint faces. Punch or
drill holes in new panels for plug welding as
shown.
WARNING: Remove ALL traces of
adhesive from outer face of ’A’ post
reinforcement before plug welding.
Cut upper ’A’ post and repair panel to form seam
welded joints with existing panels.
19. Reverse removal procedure.
20. Remove stands and lower vehicle.
77
PANEL REPAIRS NEW RANGE ROVER
4
REPAIR
LOWER ’A’ POST AND REINFORCEMENT
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
5. Remove both airbag modules.
See
SUPPLEMENTARY RESTRAINT SYSTEM,
Repair. See SUPPLEMENTARY RESTRAINT
SYSTEM, Repair.
6. Disconnect alternator.
7. Remove front bumper valance.
See CHASSIS
AND BODY, Repair.
8. Remove extension spoiler front bumper.
See
CHASSIS AND BODY, Repair.
9. Remove front grille.
See CHASSIS AND BODY,
Repair.
10. Remove windscreen.
See CHASSIS AND
BODY, Repair.
11. Remove headlamp.
See Workshop Manual -
ELECTRICAL.
12. Remove bonnet.
See CHASSIS AND BODY,
Repair.
13. Remove wheel arch liner - front.
See CHASSIS
AND BODY, Repair.
14. Remove front door assembly.
See CHASSIS
AND BODY, Repair.
15. Remove ’A’ post trim.
See CHASSIS AND
BODY, Repair.
16. Remove fascia assembly.
See CHASSIS AND
BODY, Repair.
17. Remove front wing.
Refit
NOTE: In this operation, the lower ’A’ post
and reinforcement are replaced in
combination with the upper ’A’ post and
repair panel. It is also necessary to remove the
front sidemember for access.
18. Prepare and clean panel joint faces. Punch or
drill holes in new panels for plug welding as
shown.
WARNING: Remove ALL traces of
structural adhesive from dash
reinforcement end flange before plug
welding.
Cut ’A’ post reinforcement to form a seam welded butt
joint with existing panel.
19. Reverse removal procedure.
20. Remove stands and lower vehicle.
PANEL REPAIRS
5
REPAIR
’BC’ POST REPAIR PANEL
Remove
1. Disconnect battery earth lead.
2. Raise side of vehicle.
WARNING: Support on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
5. Remove both airbag modules.
See
SUPPLEMENTARY RESTRAINT SYSTEM,
Repair. See SUPPLEMENTARY RESTRAINT
SYSTEM, Repair.
6. Disconnect alternator.
7. Remove front seat.
See CHASSIS AND BODY,
Repair.
8. Remove seat belt - front.
See CHASSIS AND
BODY, Repair.
9. Remove front seat belt adjustable mounting.
See CHASSIS AND BODY, Repair.
10. Remove B post trim.
See CHASSIS AND
BODY, Repair.
11. Remove rear door assembly.
See CHASSIS
AND BODY, Repair.
Refit
12. Prepare and clean panel joint faces. Punch or
drill holes in new ’BC’ post repair panel for plug
welding as shown. Cut panel to form seam
welded butt joints with existing panel.
13. Reverse removal procedure.
14. Remove stands and lower vehicle.
77
PANEL REPAIRS NEW RANGE ROVER
6
REPAIR
’BC’ POST REINFORCEMENT
Remove
1. Disconnect battery earth lead.
2. Raise side of vehicle.
WARNING: Support on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
5. Disconnect alternator.
6. Remove front seat.
See CHASSIS AND BODY,
Repair.
7. Remove seat belt - front.
See CHASSIS AND
BODY, Repair.
8. Remove front seat belt adjustable mounting.
See CHASSIS AND BODY, Repair.
9. Remove B post trim.
See CHASSIS AND
BODY, Repair.
10. Remove rear door assembly.
See CHASSIS
AND BODY, Repair.
Refit
NOTE: In this operation, the ’B’ post
reinforcement and ’B’ post repair panel are
replaced in combination.
11. Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding as
shown. Cut new panel to form seam welded butt
joint with existing panel.
12. Reverse removal procedure.
13. Remove stands and lower vehicle.
PANEL REPAIRS
7
REPAIR
’BC’ POST INNER PANELS
Remove
1. Disconnect battery earth lead.
2. Raise side of vehicle.
WARNING: Support on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
5. Disconnect alternator.
6. Remove front seat.
See CHASSIS AND BODY,
Repair.
7. Remove seat belt - front.
See CHASSIS AND
BODY, Repair.
8. Remove front seat belt adjustable mounting.
See CHASSIS AND BODY, Repair.
9. Remove ’B’ post trim.
See CHASSIS AND
BODY, Repair.
10. Remove rear door assembly.
See CHASSIS
AND BODY, Repair.
Refit
NOTE: In this operation, the inner panels
are replaced in combination with a ’B’ post
reinforcement and repair panel.
11. Prepare and clean panel joint faces. Punch or
drill holes in new ’BC’ post inner panels for plug
welding as shown.
12. Reverse removal procedure.
13. Remove stands and lower vehicle.
77
PANEL REPAIRS NEW RANGE ROVER
8
REPAIR
ROOF ASSEMBLY
Remove
1. Disconnect battery earth lead.
2. Disconnect all ECUs.
3. Disconnect airbags and sensor system.
4. Disconnect alternator.
5. Remove headlining - sliding roof.
See CHASSIS
AND BODY, Repair.
6. Remove sliding roof - electric.
See CHASSIS
AND BODY, Repair.
7. Remove windscreen.
See CHASSIS AND
BODY, Repair.
8. Remove front door assembly.
See CHASSIS
AND BODY, Repair.
9. Remove rear door assembly.
See CHASSIS
AND BODY, Repair.
10. Remove tailgate - upper.
See CHASSIS AND
BODY, Repair.
11. Remove seat belt - front.
See CHASSIS AND
BODY, Repair.
12. Remove front seat belt adjustable mounting.
See CHASSIS AND BODY, Repair.
13. Remove A, B, D and E post trims.
See
CHASSIS AND BODY, Repair.
14. Remove sunroof drain tube - front.
See
CHASSIS AND BODY, Repair.
15. Remove sunroof drain tube - rear.
See
CHASSIS AND BODY, Repair.
Refit
16. Prepare and clean panel joint faces. Punch or
drill holes in new roof assembly for plug welding
as shown.
WARNING: Remove ALL traces of
adhesive from joints to cant rail front and
rear corners before plug welding.
17. Reverse removal procedure.
PANEL REPAIRS
9
REPAIR
OUTER REAR QUARTER PANEL
Remove
1. Disconnect battery earth lead.
2. Raise rear of vehicle.
WARNING: Support on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
5. Disconnect alternator.
6. Remove tailgate - lower.
See CHASSIS AND
BODY, Repair.
7. Remove parcel tray support.
See CHASSIS
AND BODY, Repair.
8. Remove parcel tray support trim.
See CHASSIS
AND BODY, Repair.
9. Remove ’E’ post - exterior trim.
See CHASSIS
AND BODY, Repair.
10. Remove D and E post trims.
See CHASSIS
AND BODY, Repair.
11. Remove wheel arch liner - rear.
See CHASSIS
AND BODY, Repair.
12. Remove rear quarter light.
See CHASSIS AND
BODY, Repair.
13. Remove quarter panel rubbing strips.
See
CHASSIS AND BODY, Repair.
14. Remove rear bumper valance.
See CHASSIS
AND BODY, Repair.
15. Remove rear seat belt - left hand or right hand.
See CHASSIS AND BODY, Repair. See
CHASSIS AND BODY, Repair.
16. Remove sunroof drain tube - rear.
See
CHASSIS AND BODY, Repair.
Refit
17. Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding as
shown. Apply structural adhesive at joint to outer
wheelarch.
See Corrosion protection.
WARNING: Remove ALL traces of
adhesive from joint to lower panel before
plug welding.
18. Reverse removal procedure.
19. Remove stands and lower vehicle.
77
PANEL REPAIRS NEW RANGE ROVER
10
REPAIR
INNER REAR QUARTER PANEL
Remove
1. Disconnect battery earth lead.
2. Raise rear of vehicle.
WARNING: Support on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
5. Disconnect alternator.
6. Remove tailgate - lower.
See CHASSIS AND
BODY, Repair.
7. Remove tailgate - upper.
See CHASSIS AND
BODY, Repair.
8. Remove parcel tray support and trim.
See
CHASSIS AND BODY, Repair.
9. Remove ’E’ post - exterior trim.
See CHASSIS
AND BODY, Repair.
10. Remove ’D’ and ’E’ post trims.
See CHASSIS
AND BODY, Repair.
11. Remove wheel arch liner - rear.
See CHASSIS
AND BODY, Repair.
12. Remove rear quarterlight.
See CHASSIS AND
BODY, Repair.
13. Remove appropriate rubbing strip.
See
CHASSIS AND BODY, Repair.
14. Remove rear bumper valance.
See CHASSIS
AND BODY, Repair.
15. Remove rear seat belt - left hand or right hand.
See CHASSIS AND BODY, Repair. See
CHASSIS AND BODY, Repair.
16. Remove sunroof drain tube - rear.
See
CHASSIS AND BODY, Repair.
Refit
NOTE: In this operation, the inner rear
quarter panel, outer quarter and rear
quarter repair panel are replaced in
combination .
17. Prepare and clean panel joint faces. Apply
structural adhesive at joint to floor at lower edge
of wheelarch.
See Corrosion protection.
Plug weld at joints to floor using holes left by spot
weld cutter. Cut inner rear quarter to form seam
welded butt joints with existing panel.
WARNING: Remove ALL traces of
adhesive from joint to floor inside vehicle
before plug welding.
18. Reverse removal procedure.
19. Remove stands and lower vehicle.
PANEL REPAIRS
11
REPAIR
REAR QUARTER REPAIR PANEL
Remove
1. Disconnect battery earth lead.
2. Raise rear of vehicle.
WARNING: Support on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
5. Disconnect alternator.
6. Remove tailgate - lower.
See CHASSIS AND
BODY, Repair.
7. Remove tailgate - upper.
See CHASSIS AND
BODY, Repair.
8. Remove parcel tray support and trim.
See
CHASSIS AND BODY, Repair.
9. Remove ’E’ post - exterior trim.
See CHASSIS
AND BODY, Repair.
10. Remove ’D’ and ’E’ post trims.
See CHASSIS
AND BODY, Repair.
11. Remove wheel arch liner - rear.
See CHASSIS
AND BODY, Repair.
12. Remove rear quarterlight.
See CHASSIS AND
BODY, Repair.
13. Remove rear quarter rubbing strip.
See
CHASSIS AND BODY, Repair.
14. Remove rear bumper valance.
See CHASSIS
AND BODY, Repair.
15. Remove rear seat belt - left hand or right hand.
See CHASSIS AND BODY, Repair.
16. Remove sunroof drain tube - rear.
See
CHASSIS AND BODY, Repair.
Refit
NOTE: In this operation, the rear quarter
repair panel, outer quarter and rear quarter
repair panel are replaced in combination.
17. Cut new rear quarter repair panel to form MIG
welded butt joints with existing panels.
CAUTION: Do NOT cut into the inner
quarter during this operation.
18. Reverse removal procedure.
19. Remove stands and lower vehicle.
77
PANEL REPAIRS NEW RANGE ROVER
12
REPAIR
LOAD FLOOR SIDE
Remove
1. Disconnect battery earth lead.
2. Raise rear of vehicle.
WARNING: Support on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
5. Disconnect alternator.
6. Remove tailgate - lower.
See CHASSIS AND
BODY, Repair.
7. Remove rear bumper valance.
See CHASSIS
AND BODY, Repair.
Refit
8. Prepare and clean panel mating faces. Punch or
drill holes in new rear floor panel for plug welding
as shown. Plug weld also to spare wheel well
edges using holes left by spot weld cutter.
9. Reverse removal procedure.
10. Remove stands and lower vehicle.
REAR CROSSMEMBER PANEL
Remove
1. Disconnect battery earth lead.
2. Raise rear of vehicle.
WARNING: Support on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
5. Disconnect alternator.
6. Remove tailgate - lower.
See CHASSIS AND
BODY, Repair.
7. Remove rear bumper valance.
See CHASSIS
AND BODY, Repair.
Refit
8. Prepare and clean panel joint faces. Punch or
drill holes in new rear crossmember panel for
plug welding as shown.
9. Reverse removal procedure.
10. Remove stands and lower vehicle.
PANEL REPAIRS
13
REPAIR
REAR FLOOR EXTENSION PANEL
Remove
1. Disconnect battery earth lead.
2. Raise rear of vehicle.
WARNING: Support on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
5. Disconnect alternator.
6. Remove tailgate - lower.
See CHASSIS AND
BODY, Repair.
7. Remove rear bumper valance.
See CHASSIS
AND BODY, Repair.
Refit
8. Prepare and clean panel joint faces. Punch or
drill holes in new rear crossmember extension
panel for plug welding as shown.
9. Reverse removal procedure.
10. Remove stands and lower vehicle.
SPARE WHEEL CLOSING PANEL
Remove
1. Disconnect battery earth lead.
2. Disconnect all ECUs.
3. Disconnect airbags and sensor system.
4. Disconnect alternator.
5. Remove rear seat belt - left hand.
See
CHASSIS AND BODY, Repair.
6. Remove rear seat belt - right hand.
See
CHASSIS AND BODY, Repair.
7. Remove rear seatbelt - centre.
See CHASSIS
AND BODY, Repair.
Refit
8. Prepare and clean panel joint faces. Punch or
drill holes in new spare wheel closing panel for
plug welding as shown.
9. Reverse removal procedure.
77
PANEL REPAIRS NEW RANGE ROVER
14
REPAIR
LOWER PANEL
Remove
1. Disconnect battery earth lead.
2. Disconnect all ECUs.
3. Disconnect airbags and sensor system.
4. Disconnect alternator.
5. Remove tailgate - lower.
See CHASSIS AND
BODY, Repair.
6. Remove tailgate striker.
See CHASSIS AND
BODY, Repair.
7. Remove rear bumper valance.
See CHASSIS
AND BODY, Repair.
Refit
8. Prepare and clean panel joint faces. Punch or
drill holes in new lower panel for plug welding as
shown.
WARNING: remove ALL traces of adhesive
from joints to quarter panels before plug
welding.
9. Reverse removal procedure.